Suzuki GRAND VITARA - User manual

Table of Contents 3- i

3

Section 3

CONTENTS

Driveline / Axle

Precautions .................................................3-1

Precautions............................................................. 3-1

Precautions for Driveline / Axle ............................. 3-1

Drive Shaft / Axle ..................................... 3A-1

Front .........................................................................3A-1

General Description .............................................3A-1

Front Drive Shaft Construction............................3A-1

Diagnostic Information and Procedures............3A-1

Front Drive Shaft Symptom Diagnosis ................ 3A-1

Repair Instructions ..............................................3A-2

Front Drive Shaft Boot and Joint Check.............. 3A-2

Front Drive Shaft Components ........................... 3A-2

Front Drive Shaft Assembly Removal and

Installation......................................................... 3A-3

Front Drive Shaft Disassembly and

Assembly .......................................................... 3A-3

Specifications.......................................................3A-6

Tightening Torque Specifications........................ 3A-6

Special Tools and Equipment .............................3A-6

Recommended Service Material ......................... 3A-6

Special Tool ........................................................ 3A-6

Rear ..........................................................................3A-7

General Description .............................................3A-7

Rear Drive Shaft Construction ............................ 3A-7

Repair Instructions ..............................................3A-7

Rear Drive Shaft Components ............................ 3A-7

Rear Drive Shaft Assembly Removal and

Installation......................................................... 3A-8

Rear Drive Shaft Disassembly and

Assembly .......................................................... 3A-8

Specifications.......................................................3A-9

Tightening Torque Specifications........................ 3A-9

Special Tools and Equipment .............................3A-9

Recommended Service Material ......................... 3A-9

Special Tool ........................................................ 3A-9

Differential................................................ 3B-1

Front .........................................................................3B-1

General Description .............................................3B-1

Front Differential Construction ............................ 3B-1

Diagnostic Information and Procedures............3B-1

Front Differential Symptom Diagnosis................. 3B-1

Repair Instructions ..............................................3B-2

Front Differential Oil Change .............................. 3B-2

Front Differential Unit Components..................... 3B-3

Front Differential Dismounting and

Remounting.......................................................3B-3

Front Differential Components ............................3B-4

Front Differential Assembly Disassembly

and Reassembly ...............................................3B-5

Front Differential Inspection ..............................3B-17

Specifications.....................................................3B-18

Tightening Torque Specifications......................3B-18

Special Tools and Equipment ...........................3B-18

Recommended Service Material .......................3B-18

Special Tool ......................................................3B-18

Rear ........................................................................3B-21

General Description ...........................................3B-21

Rear Differential Construction ...........................3B-21

Diagnostic Information and Procedures..........3B-21

Rear Differential Symptom Diagnosis ...............3B-21

Repair Instructions ............................................3B-21

Rear Differential Oil Change .............................3B-21

Rear Differential Unit Components ...................3B-21

Rear Differential Dismounting and

Remounting.....................................................3B-22

Rear Differential Components...........................3B-23

Rear Differential Assembly Disassembly

and Reassembly .............................................3B-24

Rear Differential Inspection...............................3B-36

Specifications.....................................................3B-36

Tightening Torque Specifications......................3B-36

Special Tools and Equipment ...........................3B-37

Recommended Service Material .......................3B-37

Special Tool ......................................................3B-37

Transfer .................................................... 3C-1

Motor-Shift Type (Transfer with Shift

Actuator) ................................................................3C-1

Precautions...........................................................3C-1

Transfer Warning ................................................3C-1

Precautions in Diagnosing Trouble .....................3C-1

General Description .............................................3C-1

Transfer Description............................................3C-1

Transfer Shift Control System Components........3C-2

4WD Control System Description........................3C-3

Function of 4WD Control System

Component........................................................3C-5

4WD Control System Operation..........................3C-5

4WD Control System Wiring Circuit Diagram....3C-11

Terminal Arrangement of 4WD Control

Module ............................................................3C-12

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3-ii Table of Contents

Input / Output Signal Table of 4WD Control

Module ............................................................3C-12

On-Board Diagnostic System Description.........3C-12

CAN Communication System Description.........3C-13

Diagnostic Information and Procedures..........3C-14

4WD Control System Check .............................3C-14

Transfer Position Indicator Operation Check ....3C-17

4WD Control System Operation Inspection ......3C-17

Visual Inspection ...............................................3C-18

DTC Check........................................................3C-19

DTC Clearance .................................................3C-20

DTC Table.........................................................3C-20

Fail-Safe Table..................................................3C-21

Scan Tool Data .................................................3C-22

Scan Tool Data Definitions................................3C-22

4WD Control Symptom Diagnosis.....................3C-23

Transfer Position Indicator Does Not Come

ON at Ignition Switch ON but Engine Stops....3C-24

Transfer Position Indicator Remains ON

Steady at Ignition Switch ON ..........................3C-26

DTC C1213: Transfer Switch Circuit Open .......3C-27

DTC C1214: Transfer Switch Circuit Short .......3C-28

DTC C1223 / C1235: Transfer Shift

Actuator Motor Position Switch 1 Circuit

Open / Transfer Shift Actuator Motor Position

Switch 2 Circuit Open .....................................3C-30

DTC C1224 / C1236: Transfer Shift

Actuator Motor Position Switch 1 Circuit

Short / Transfer Shift Actuator Motor Position

Switch 2 Circuit Short......................................3C-32

DTC C1227: 4L/N Switch Circuit Open .............3C-34

DTC C1228: 4L/N Switch Circuit Short .............3C-35

DTC C1230: Transfer Actuator Circuit

Malfunction......................................................3C-37

DTC C1237: Center Differential Lock Switch

Circuit Open ....................................................3C-38

DTC C1238: Center Differential Lock Switch

Circuit Short ....................................................3C-40

DTC C1240: 4WD Control Module Power

Supply Circuit Malfunction ..............................3C-41

DTC C1243: Internal Circuit Malfunction of

4WD Control Module.......................................3C-42

DTC C1246: Clutch Pedal Position (CPP)

Switch Circuit Short.........................................3C-43

DTC U1073: Control Module Communication

Buss Off ..........................................................3C-44

DTC U1100: Lost Communication with ECM ....3C-46

DTC U1101: Lost Communication with TCM ....3C-48

DTC U1121: Lost Communication with ABS

Hydraulic Unit / Control Module ......................3C-50

Inspection of 4WD Control Module and Its

Circuits ............................................................3C-51

Repair Instructions ............................................3C-54

Transfer Oil Level Check...................................3C-54

Transfer Oil Change..........................................3C-54

Transfer Oil Seal Removal and Installation.......3C-55

Transfer Switch Removal and Installation.........3C-55

Transfer Switch Inspection................................3C-56

4WD Control Module Removal and

Installation.......................................................3C-56

Transfer Assembly Dismounting and

Remounting.....................................................3C-57

Transfer Assembly Components .......................3C-58

Transfer Assembly Disassembly and

Reassembly ....................................................3C-59

Transfer Assembly Inspection ...........................3C-67

Input Gear Assembly, Counter Gear

Assembly, Front Output Shaft Assembly

and Rear Output Shaft Assembly

Components....................................................3C-69

Input Gear Assembly Disassembly and

Reassembly ....................................................3C-70

Counter Gear Assembly Disassembly

and Reassembly .............................................3C-71

Front Output Shaft Assembly Disassembly

and Reassembly .............................................3C-71

Rear Output Shaft Assembly Disassembly

and Reassembly .............................................3C-72

Specifications.....................................................3C-73

Tightening Torque Specifications......................3C-73

Special Tools and Equipment ...........................3C-73

Recommended Service Material .......................3C-73

Special Tool ......................................................3C-74

Non-Shift Type (Transfer without Shift

Actuator) ..............................................................3C-75

Precautions.........................................................3C-75

Transfer Warning ..............................................3C-75

General Description ...........................................3C-75

Transfer Construction........................................3C-75

Diagnostic Information and Procedures..........3C-76

Transfer Symptom Diagnosis............................3C-76

Repair Instructions ............................................3C-77

Transfer Oil Change..........................................3C-77

Transfer Oil Level Check......

...

..........................3C-77

Transfer Oil Seal Removal and Installation.......3C-77

Transfer Assembly Dismounting and

Remounting.....................................................3C-77

Transfer Assembly Components .......................3C-78

Transfer Assembly Disassembly and

Reassembly ....................................................3C-80

Input Gear Assembly Disassembly and

Reassembly ....................................................3C-86

Front Output Shaft Assembly Disassembly

and Reassembly .............................................3C-86

Rear Output Shaft Assembly Disassembly

and Reassembly .............................................3C-86

Specifications.....................................................3C-87

Tightening Torque Specifications......................3C-87

Special Tools and Equipment ...........................3C-87

Recommended Service Material .......................3C-87

Special Tool ......................................................3C-87

Propeller Shafts....................................... 3D-1

Precautions...........................................................3D-1

Propeller Shaft Caution .......................................3D-1

General Description .............................................3D-1

Propeller Shaft Construction ...............................3D-1

Diagnostic Information and Procedures............3D-2

Propeller Shaft Symptom Diagnosis ...................3D-2

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Table of Contents 3-iii

Repair Instructions ..............................................3D-2

Propeller Shaft Joint Check ................................3D-2

Propeller Shaft Removal and Installation ............3D-2

Propeller Shaft Disassembly and Assembly .......3D-3

Propeller Shaft Inspection ...................................3D-5

Specifications.......................................................3D-5

Tightening Torque Specifications........................3D-5

Special Tools and Equipment .............................3D-6

Recommended Service Material .........................3D-6

Special Tool ........................................................3D-6

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3-1 Precautions:

Precautions

Precautions for Driveline / Axle

S5JB0A3000001

Differential Gear Oil Note

Refer to “Differential Gear Oil Note: in Section 00”.

Fastener Caution

Refer to “Fastener Caution: in Section 00”.

Precautions for Transfer

Refer to “Precautions in Diagnosing Trouble: Motor-Shift Type (Transfer with Shift Actuator) in Section 3C”.

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Drive Shaft / Axle: Front 3A-1

Drive Shaft / Axle

Front

General Description

Front Drive Shaft Construction

S5JB0A3111001

A constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a

constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies. The drive shaft

can slide through the tripod joint in the extension / contraction direction.

Diagnostic Information and Procedures

Front Drive Shaft Symptom Diagnosis

S5JB0A3114001

Condition Possible cause Correction / Reference Item

Abnormal noise: When

starting

Loose wheel nut(s) Tighten wheel nut(s) referring to “Wheel

Removal and Installation: in Section 2D”.

Loose drive shaft flange bolt(s) Tighten drive shaft flange bolt(s) referring to

“Front Drive Shaft Assembly Removal and

Installation: Front”.

Broken or damaged wheel bearing Replace referring to “Front Wheel Hub, Disc,

Nut and Bearing Check: in Section 2B”.

Abnormal noise: When

making turns

Grease leakage from boot Replace boot and apply grease referring to

“Front Drive Shaft Disassembly and Assembly:

Front”.

Worn or broken drive shaft joint Replace drive shaft joint referring to “Front

Drive Shaft Disassembly and Assembly:

Front”.

Abnormal noise: When

running

Broken drive shaft joint Replace drive shaft joint referring to “Front

Drive Shaft Disassembly and Assembly:

Front”.

Poorly lubricated or worn joint Lubricate or replace joint referring to “Front

Drive Shaft Disassembly and Assembly:

Front”.

Loose drive shaft flange bolt(s) Tighten drive shaft flange bolt(s) referring to

“Front Drive Shaft Assembly Removal and

Installation: Front”.

Vibration Worn drive shaft joint Replace drive shaft joint referring to “Front

Drive Shaft Disassembly and Assembly:

Front”.

Deformed drive shaft Replace referring to “Front Drive Shaft

Disassembly and Assembly: Front”.

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3A-2 Drive Shaft / Axle: Front

Repair Instructions

Front Drive Shaft Boot and Joint Check

S5JB0A3116001

• Check boot for tear. If even a small tear is found, replace with new one.

• Check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found.

Front Drive Shaft Components

S5JB0A3116002

I5JB0A311001-01

I5JB0A311002-03

[A]: Right side drive shaft assembly 4. Boot band (Large) 9. Drive shaft nut

: After tightening nut, caulk nut

securely.

[B]: Left side drive shaft assembly 5. Boot (Differential side) 10. Front drive shaft flange nut

1. Circlip 6. Boot band (Small) : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)

2. Differential side joint (Constant velocity tripod joint)

: Apply yellow grease included in spare part to joint.

7. Wheel side joint assembly (Constant velocity

ball joint)

: Never disassemble.

:80 N⋅m (8.0 kgf-m, 58.0 lb-ft)

3. Snap ring 8. Tripod joint spider : Do not reuse.

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Drive Shaft / Axle: Front 3A-3

Front Drive Shaft Assembly Removal and

Installation

S5JB0A3116003

Removal

1) Undo caulking (1) and remove drive shaft nut (2).

2) Hoist vehicle and remove wheel.

3) Drain front differential oil.

4) Disconnect tie-rod end from steering knuckle

referring to “Steering Knuckle Removal and

Installation: in Section 2B”.

5) Remove stabilizer joint from stabilizer bar.

6) Remove brake hose mounting bolt.

7) Remove suspension control arm referring to

“Suspension Control Arm Removal and Installation:

in Section 2B”.

8) Remove front drive shaft flange nuts (1).

9) Remove drive shaft assembly from front differential.

CAUTION

!

To prevent breakage of boots (wheel side and

differential side), do not contact them with

other parts when removing drive shaft

assembly.

Installation

CAUTION

!

• Be careful not to damage oil seals and

boots when installing drive shaft.

• Do not hit joint boot with hammer.

Inserting joint only by hands is allowed.

• Make sure that differential side joint is

inserted fully and its snap ring is seated as

it was.

Install drive shaft assembly by reversing removal

procedure and noting the following points.

• Tighten each bolts and nuts to the specified torque

referring to “Front Drive Shaft Components: Front”

and “Front Suspension Construction: in Section 2B”.

Front Drive Shaft Disassembly and Assembly

S5JB0A3116004

Disassembly

CAUTION

!

• Disassembly of wheel side joint assembly

is not allowed. If any noise or damage

exists in it, replace it as assembly.

• Do not disassemble tripod joint spider. If

any malcondition is found in it, replace it

as differential side joint assembly.

1) Draw hooks (2) of boot big band together and

remove differential side boot big band (1).

I5JB0A311003-01

1

I5JB0A311004-01

I5JB0A311005-01

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3A-4 Drive Shaft / Axle: Front

2) Wipe off grease from shaft and take off snap ring (1)

using snap ring plier (2).

3) Remove tripod joint spider (1) using 3 arms puller

(2).

CAUTION

!

To prevent any problem caused by washing

solution, do not wash tripod joint except its

housing. Degreasing of tripod joint with cloth

is allowed.

4) Remove differential side boot small band, and then

pull out differential side boot from shaft.

Assembly

Judging from abnormality noted before disassembly and

what is found through visual check of component parts

after disassembly, prepare replacing parts and proceed

to reassembly.

Make sure that tripod joint housing is washed thoroughly

and air dried.

Replace boot with new one.

CAUTION

!

• Do not wash boots in degreaser such as

gasoline or kerosene. etc. Washing in

degreaser causes deterioration of boot.

• To ensure full performance of joint as

designed, apply grease of specified

volume and color to joint.

1) Wash disassembled parts (except boots). After

washing, dry parts completely by blowing air.

2) Clean boots with cloth.

3) Set new differential side small band and new

differential side boot (1) on shaft temporarily, and

then apply grease to tripod joint (2). Use specified

grease in tube included in spare parts.

4) Install tripod joint spider (3) on shaft using special

tool with hammer, directing its chamfered spline

toward wheel side, and then fasten it with new snap

ring (4) using snap ring plier (5).

Special tool

(A): 09913–80113

I5JB0A311008-01

I3RH0A311004-01

I5JB0A311009-01

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Drive Shaft / Axle: Front 3A-5

5) Apply grease (including in spare parts) to inside of

tripod joint housing (1), joint it with tripod joint.

Grease color

“A”: Yellow

Amount

“A”: 127 – 137 g (4.5 – 4.8 oz) (right side)

“A”: 170 – 180 g (6.0 – 6.3 oz) (left side)

6) Fit boot to grooves of shaft and housing.

7) Insert screw driver into boot and allow air to enter

boot so that air pressure in boot becomes the same

as atmospheric pressure.

CAUTION

!

• Bend each boot band against forward

rotation.

• Do not squeeze or distort boot when

fastening it with bands. Distorted boot

caused by squeezing air may reduce its

durability.

8) Place differential side boot new big band (3) and new

small band (4) onto boot putting band outer end (1)

against forward rotation (2) as shown in figure.

9) Fasten differential side boot big band.

• For differential side boot big band

Fasten band (1) by drawing hooks (2) with special

tool and engage hooks (3) in slot and window (4).

Special tool

(A): 09943–57010

• For differential side boot small band

Fasten band (5) securely using special tool.

NOTE

Fasten boot small band securely until

complete contact “a” is obtained.

Special tool

(A): 09943–57010

I4RS0B310003-01

I5JB0A311006-01

(A)

1

4

2

3

(A)

5

“a”

I5JB0A311007-02

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3A-6 Drive Shaft / Axle: Front

Specifications

Tightening Torque Specifications

S5JB0A3117001

NOTE

The specified tightening torque is also described in the following.

“Front Drive Shaft Components: Front”

Reference:

For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0A3118001

NOTE

Required service material is also described in the following.

“Front Drive Shaft Components: Front”

Special Tool

S5JB0A3118002

09913–80113 09943–57010

Bearing installer Band compressor

)) / )

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Drive Shaft / Axle: Rear 3A-7

Rear

General Description

Rear Drive Shaft Construction

S5JB0A3121002

Refer to “Front Drive Shaft Construction: Front”.

Repair Instructions

Rear Drive Shaft Components

S5JB0A3126007

I5JB0A312001-02

1. Differential side joint (Constant velocity tripod joint)

: Apply yellow grease included in spare part to joint.

5. Boot band (Small) 9. Rear drive shaft flange nut

2. Snap ring 6. Wheel side joint (Constant velocity ball joint)

: Never disassemble.

: 200 N⋅m (20.0 kgf-m, 145.0 lb-

ft)

3. Boot band (Large) 7. Tripod joint spider : 80 N⋅m (8.0 kgf-m, 58.0 lb-ft)

4. Boot (Differential side) 8. Drive shaft nut

: After tightening nut, caulk nut securely.

: Do not reuse.

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3A-8 Drive Shaft / Axle: Rear

Rear Drive Shaft Assembly Removal and

Installation

S5JB0A3126008

Removal

1) Undo caulking (1) of drive shaft nut (2) and then

remove drive shaft nut.

2) Hoist vehicle and remove wheel.

3) Give match mark rear drive shaft flange (3) and rear

drive shaft (4) as shown in figure, and then remove

rear drive shaft flange nuts (1), and then remove rear

drive shaft.

Installation

Install drive shaft assembly by reversing removal

procedure and noting the following points.

• Install rear drive shaft (1) aligning match marks (2).

CAUTION

!

• Protect oil seals and boots from any

damage, preventing them form

unnecessary contact while installing drive

shaft.

• Do not hit joint boot with hammer.

Inserting joint only by hands is allowed.

• Make sure that differential side joint is

inserted fully and its snap ring is seated as

it was.

• Tighten each nuts to specified torque referring to

“Rear Drive Shaft Components: Rear”.

Rear Drive Shaft Disassembly and Assembly

S5JB0A3126009

Disassembly

Refer to “Front Drive Shaft Disassembly and Assembly:

Front”.

Assembly

Assemble rear drive shaft assembly referring to “Front

Drive Shaft Disassembly and Assembly: Front” and

noting the following points which are different from that

of the front drive shaft assembly.

• Apply grease to differential side joint.

Grease color

: Yellow

Amount

: 197 – 207 g (6.9 – 7.3 oz)

• Install tripod joint spider (1) on shaft by using special

tool with hammer, directing its chamfered spline

toward wheel side, and then fasten it with new snap

ring (2) using snap ring plier (3).

Special tool

(A): 09913–84510

2. Match mark

I5JB0A311003-01

1

3

2

4

I5JB0A312002-02

2

1

I5JB0A312003-01

I5JB0A312004-03

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Drive Shaft / Axle: Rear 3A-9

Specifications

Tightening Torque Specifications

S5JB0A3127001

NOTE

The specified tightening torque is also described in the following.

“Rear Drive Shaft Components: Rear”

Reference:

For the tightening torque of fastener not specified in this section, refer to “Fastener Information: in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0A3128001

NOTE

Required service material is also described in the following.

“Rear Drive Shaft Components: Rear”

Special Tool

S5JB0A3128002

09913–84510

Bearing installer

)

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3B-1 Differential: Front

Differential

Front

General Description

Front Differential Construction

S5JB0A3211001

The differential assembly uses a hypoid bevel pinion and gear.

The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and

specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between bevel pinion and

gear, it is mandatory to lubricate them by hypoid gear oil.

Diagnostic Information and Procedures

Front Differential Symptom Diagnosis

S5JB0A3214001

Condition Possible cause Correction / Reference Item

Gear noise Deteriorated or water mixed lubricant Repair and replenish referring to “Front

Differential Oil Change: Front”.

Inadequate or insufficient lubricant Repair and replenish referring to “Front

Differential Oil Change: Front”.

Maladjusted backlash between drive

bevel pinion and gear

Adjust as prescribed referring to “Front

Differential Assembly Disassembly and

Reassembly: Front”.

Improper tooth contact in the mesh

between drive bevel pinion and gear

Adjust or replace referring to “Front Differential

Assembly Disassembly and Reassembly:

Front”.

Loose drive bevel gear securing bolts Replace or retighten referring to “Front

Differential Assembly Disassembly and

Reassembly: Front”.

Damaged differential gear(s) or

differential pinion(s)

Replace referring to “Front Differential

Inspection: Front”.

Bearing noise (Constant noise) Deteriorated or water

mixed lubricant

Repair and replenish referring to “Front

Differential Oil Change: Front”.

(Constant noise) Inadequate or

insufficient lubricant

Repair and replenish referring to “Front

Differential Oil Change: Front”.

(Noise while coasting) Damaged

bearing(s) of drive bevel pinion

Replace referring to “Front Differential

Inspection: Front”.

(Noise while turning) Damaged

differential side bearing(s) or axle

bearing(s)

Replace referring to “Front Differential

Inspection: Front”.

Oil leakage Clogged breather plug Clean.

Worn or damaged oil seal Replace.

Excessive oil Adjust oil level referring to “Front Differential

Oil Change: Front”.

Loose differential carrier bolts Replace or retighten.

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Differential: Front 3B-2

Repair Instructions

Front Differential Oil Change

S5JB0A3216012

1) Before changing or inspecting oil, be sure to stop

engine and lift vehicle horizontally.

2) With vehicle lifted up, check leakage.

If leakage exists, correct it.

NOTE

Whenever vehicle is hoisted for any other

service work than oil change, also be sure to

check for oil leakage.

3) Remove oil filler plug (2).

4) Remove drain plug (1), and drain old oil.

5) Apply sealant to thread of drain plug (1), and tighten

it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond

No.1217G)

Tightening torque

Differential oil drain plug (a): 23 N·m (2.3 kgf-m,

17.0 lb-ft)

6) Pour new specified oil until oil level reaches bottom

of oil filler plug hole (3) as shown in figure.

NOTE

• Hypoid gear oil must be used for

differential.

• It is highly recommended to use API GL-5

80W-90 gear oil.

Differential oil specification

: API GL-5 (For SAE classification, refer to

viscosity chart [A] in figure.)

Differential oil capacity (Reference)

: 0.9 – 1.1 liters (1.9/1.6 – 2.3/1.9 US/Imp. pt.)

7) Apply sealant to thread of level / filler plug, and then

tighten it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond

No.1217G)

Tightening torque

Differential oil level / filler plug (b): 23 N·m (2.3

kgf-m, 17.0 lb-ft)

I5JB0A321004-02

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3B-3 Differential: Front

Front Differential Unit Components

S5JB0A3216007

Front Differential Dismounting and Remounting

S5JB0A3216008

Dismounting

1) Lift up vehicle and drain front differential oil.

2) Remove front drive shafts referring to “Front Drive

Shaft Assembly Removal and Installation: Front in

Section 3A”.

3) Remove front suspension frame with front differential

referring to “Front Suspension Frame, Stabilizer Bar

and/or Bushings Removal and Installation: in

Section 2B”.

4) Remove mounting bolts (1), and then take off front

differential from front suspension frame (2).

2

1

3

7

(a)

5

(a)

(b)

8

6

(b)

4

(a)

5

(a)

10

(c)

9

I5JB0A321001-05

1. Front differential 8. Rear mounting bracket bolt

2. Right mounting bracket 9. Damper

3. Right mounting bolt 10. Damper bolt

4. Differential mounting bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)

5. Rear mounting bolt : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)

6. Rear mounting bracket : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

7. Right mounting bracket bolt

1

2

I5JB0A321002-01

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Differential: Front 3B-4

Remounting

Reverse dismounting procedure for remounting noting the following.

• Tighten each bolts and nuts referring to “Front Differential Unit Components: Front”, “Front Drive Shaft Components:

Front in Section 3A” and “Front Suspension Frame, Stabilizer Bar and/or Bushings Components: in Section 2B”.

• Fill front differential oil referring to “Front Differential Oil Change: Front”.

Front Differential Components

S5JB0A3216001

(a)

18

(a)

18

(b)

24

19

9

21

15

14

16

17

14

10

11

17

16

5

26

2

4

13

23

12

10

(c)

22

3

6

7

1

A

8

(a)

25

15

20

I5JB0A321003-08

1. Universal joint flange 17. Pinion washer

2. Hypoid gear set 18. Retainer bolt

3. Bevel pinion spacer 19. Differential side right retainer

: Apply sealant 99000-31260 to mating surface of right retainer,

carrier and rear cover.

4. Shim 20. Shim

5. Rear bearing 21. Front drive shaft retainer

: Apply sealant 99000-31260 to mating surface of drive shaft

retainer, carrier and rear cover.

6. Front bearing 22. Bevel gear bolt

: Apply thread lock cement 99000-32110 to thread part of bolt.

7. Oil seal

: Apply grease 99000-25010 to oil seal lip.

23. Rear cover

8. Flange nut

: After tightening nut so as rotation torque of bevel pinion shaft to be

in specified value, caulk nut securely.

24. Rear cover bolt No.1 bolt

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3B-5 Differential: Front

Front Differential Assembly Disassembly and

Reassembly

S5JB0A3216010

Disassembly

1) Remove front differential right mounting (1) and rear

mounting (2).

2) Drive out front drive shaft (1) from front shaft retainer

(2) using plastic hammer (3).

3) Remove differential side right retainer and front drive

shaft retainer, and then remove rear cover (1).

4) Disassembly front drive shaft retainer as follows, if

necessary.

a) Remove oil seal (1) from front drive shaft retainer

using special tool.

Special tool

(A): 09913–50121

b) Remove snap ring (1) using snap ring plier.

c) Drive out front drive shaft bearing using special

tools.

Special tool

(A): 09930–30104

(B): 09941–64511

9. Differential carrier

: Apply sealant 99000-31260 to mating surface of carrier and rear

cover.

25. Rear cover bolt No.2 bolt

10. Differential pinion 26. Differential right case

11. Differential gear : 50 N⋅m (5.0 kgf-m, 36.5 lb-ft)

12. Pinion shaft : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)

13. Differential left case : 40 N⋅m (4.0 kgf-m, 29.5 lb-ft) + 50°

14. Thrust washer : Do not reuse.

15. Differential side bearing : Apply differential oil.

16. Spring washer

1

2

I5JB0A321005-01

I5JB0A321006-01

1

I5JB0A321007-01

1

(A)

I5JB0A321008-01

1

I5JB0A321009-01

(B)

(A)

I5JB0A321010-01

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Differential: Front 3B-6

5) Support differential side right retainer (1) with soft

jawed vise and remove oil seal (2) from differential

side right retainer using special tool, if necessary.

Special tool

(A): 09913–50121

6) Take out differential assembly (1), outer race and

shim all at once.

7) Pull out differential side bearing (1) using special

tools.

Special tool

(A): 09913–65135

(B): 09925–86010

8) Remove drive bevel gear (hypoid gear), differential

gears, differential pinions and pinion shaft as follows.

a) With aluminum plates (2) placed on vise first,

grip differential case with it and remove drive

bevel gear (hypoid gear) (3) by removing its bolts

(1).

b) Remove pinion shaft (1), differential gears,

washers, differential pinions, spring washers and

thrust washers.

9) Remove drive bevel pinion (hypoid gear) assembly

as follows.

a) Hold joint flange with special tool and then

remove flange nut by using power wrench (4 –

10 magnification) (2).

Special tool

(A): 09922–66021

1

(A)

2

I5JB0A321011-01

1

I5JB0A321012-02

1

(B)

(A)

I5JB0A321013-02

1. Socket wrench

3

2

1

I5JB0A321014-02

1

I5JB0A321015-02

(A)

2

1

I5JB0A321016-02

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3B-7 Differential: Front

b) Make mating marks (1) on drive bevel pinion and

companion flange.

CAUTION

!

Do not make mating mark on the coupling

surface of the flange.

c) Remove flange (2) from drive bevel pinion. Use

special tool if it is hard to remove.

Special tool

(A): 09913–65135

(B): 09925–88210

d) Remove drive bevel pinion (1) with rear bearing,

shim and spacer from carrier.

If it is hard to remove, screw an used nut (2) into

drive bevel pinion and hammer (3) on that nut

with a plastic hammer but never directly on drive

bevel pinion.

e) Remove drive bevel pinion rear bearing (2) by

using bearing puller (3) and hydraulic press.

CAUTION

!

To avoid rear bearing from being damaged,

support it at flat side of bearing puller.

10) Remove oil seal (1) using special tool.

Special tool

(A): 09913–50121

11) Using a hammer and brass bar (1), drive out front

bearing outer race (2).

2

(B)

(A)

2

1

I5JB0A321017-02

3

2

1

I5JB0A321018-01

1. Drive bevel pinion

I1JA01322006-01

(A)

1

I5JB0A321019-01

I5JB0A321020-01

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