1987 SUZUKI GRAND VITARA Service Repair Manual

2) Using spring pin remover (special tool), drive
2 spring pins out of front drive shift shaft
@ and reduction shift shaft 0.
Spring pin remover @ : (09922-85811).
Fig. 14-24
3) Remove forks and shift shafts.
NOTE:
At this time, locating ball and spring will jump
out of hole, use care not to lose them.
Fig. 14-25
4) Hammer output rear shaft with a plastic
hammer to drive it out of center case.
5) Pull out counter gear,
Remove counter shaft
loosening counter shaft
bearings and spacer.
from center case by
lock plate bolt.
Fig. 14-27
6) Remove input shaft from center case by
hammering thick part of case or input
shaft center with a plastic hammer.
Fig. 14-28
14-10
Fig. 14-26

7) Remove output shaft rear bearing and
retainer together by using bearing puller.
After removing bearing, speedometer drive
gear, thrust washer, output low gear and
needle roller bearing can be removed.
Fig. 14-29
8) Remove front drive clutch hub circlip and
pull clutch hub off shaft by using bearing
puller and puller attachment (special tool A).
NOTE:
Use care to prevent damage to needle roller
bearing in output rear shaft when removing
clutch hub.
/(A) 0992638010
Fig. 14-30
9) Remove front bearing by using bearing
puller and puller attachment (special tool
A).
NOTE:
Use care to prevent damage to needle roller
bearing in output rear shaft while bearing is
being removed.
(A) 09926-58010
Fig. 14-31
10) When input shaft is removed or center case
and rear case are separated, input shaft
bearings may come off. In such a case,
bearings can be removed from shaft by using
bearing puller.
**ita“+
Fig. 14-32
14-11

11) When input shaft is removed, front bearing
may be left in case. In this case, after remov-
ing oil seal and circlip, bearing can be taken
out of case by using bearing installer (special
tool).
Bearing installer @ : (09913-75810)
Fig. 14-33
Transfer Rear Case
1) When center case and rear case are separated,
input shaft may be left in rear case. In this
case, remove input shaft from rear case by
hammering thick part of case with a plastic
hammer.
Fig. 14-34
14-7. INSPECTION OF COMPONENTS
Gear Teeth
Inspect gear teeth 0, internal teeth of rear
clutch sleeve @ and clutch teeth of gear 3. for
wear, cracking, chipping and other
malcondition. Replace gear or sleeve as necessary.
Fig. 14-35
Fig. 14-36
Locating Spring
Check each shifter fork shaft locating spring for
strength by measuring its free length. If length is
noted to be less than service limit, replace it.
Free length of
locating spring
14-12

Fig. 14-37
Bearings
Check each bearing by spinning its outer race by
hand to “feel” smoothness of rotation. Replace
bearing if noted to exhibit sticking, resistance
or abnormal noise when spun or rotated by
hand.
Fig. 14-38
Side Clearance of Gears
With gear, bearing and thrust washer installed
on shaft, check for side clearances of gears.
If clearance exceeds service limit, replace thrust
washer.
I
Side clearance
of gear StandardService limitI
outputlow gear0.175 - 0.325mm0.7mm
gearshigh gear(0.007 - 0.012in)(0.027in)
Fig. 14-40 Output low gear
Gear Shift Shafts
Check each part as indicated in below figures for
uneven wear. Replace defective parts.
Fig. 14-41
14-13
Fig. 14-39 Output high gear

4WD Gear Shift Lever
Check lower end of gear shift lever where gear
shift fork shaft contacts @ for wear and any
kind of damage. Worn or damaged shift lever
must be replaced with new one.
14-8. REASSEMBLY
NOTE:
l All parts to be used in reassembly must be
perfectly clean.
l Oil or grease sliding and rubbing surfaces of
transfer components just before using them
in reassembly with gear oil and SUZUKI
SUPER GREASE A (99000-25010).
l Oil seals, “0” rings, gaskets and similar sealing
members must be in perfect condition. For
these members, use replacement parts in
stock.
l Tightening torque is specified for important
fasteners- mainly bolts - of transfer and
other components. Use torque wrenches and
constantly refer to specified data given in
P. 14-23.
Fig. 14-42
Input Shaft
Press-fit bearings onto both sides of input shaft
by using bearing installer (special tool).
Bearing installer (A) : (09913-84510)
(A)
Fig. 14-43
14-14

Output Rear Shaft
Install following parts onto shaft in such order
and directions as prescribed in the figure.6 9
1. Circlip
2.Hub
3.Bearing4.Bearingouter ring
5. Thrust washer
6.Outputhigh gear7.Bearing(long)
8. Output rear shaft
9.Sleeve
10.Bearing (short)
11.Outputlowgaar12.Thrust washer
13. Speed meter drive gear
14.Bearing15.Retainer
Fig. 14-44
1) After installing bearing (long), high gear and
thrust washer, press-fit bearing 1. and then
hub @ by using bearing installer (special
tool).
Bearing installer (A) : (0991384510)
Fig. 14-45
2) Fit circlip @ securely into groove in shaft.
Fig. 14-46
3) After installing sleeve, bearing (short), low
gear and thrust washer, press-fit speedometer
drive gear by using bearing installer (special
tool).
Bearing installer (A) : (09913-84510)
(A)
Fig. 14-47
4) Press-fit bearing @ and the retainer @ by
using bearing installer (special tool).
Bearing installer (A) : (0991384510)
Fig. 14-4814-15

Shim Adjustment of Input and Output Shafts
Clearance in thrust direction of both input and
output shafts is adjusted by putting shims
between input shaft rear bearing and rear case
for input shaft and between output shaft rear
bearing and rear case for output shaft.
As thrust clearance is specified as follows
determine shim thickness to meet specification
according to the following procedures.
Thrust clearance0.05 - 0.15 mm
specification(0.002 - 0.006 in.)
[Input shaft]
1) Take measurement “A” of rear case as shown
in figure below by using depth gauge,
2) Take measurement “6” of center case with
bearing circlip installed.
3) Take measurement“C” (between bearing
inner races) of input shaft with bearings
installed, by using micrometer.
NOTE:
l Before measuring, make sure that each bearing
is free from abnormal noise or resistance by
spinning its outer race.
l Each measurement in above steps 1) to 3)
must be taken accurately in careful manner,
If shim thickness is determined based on
rough measurement, clearance of each shaft in
thrust direction will not satisfy specification.
And improper clearance may cause oil leakage,
broken bearing and abnormal noise.
l Take the same measurement at 3 to 4 diffe-
rent positions and use their mean.
6
1.1.Center caseCenter case5.5.Bearing circlipBearing circlip
2.2.Rear caseRear case6.6.GasketGasket
3.3.Input shaftInput shaft7.7.Gasket thicknessGasket thickness4. Output shaft4. Output shaft(0.3 mm or 0.012 in)(0.3 mm or 0.012 in)
Fig.Fig.14-48-14-48-11
4) Using measurements obtained in steps 1) to 3)
and equation described below, calculate shim
thickness which is necessary for proper
thrust clearance.
Thrust clearance = (“A” + “B” + Gasket
thickness) - “C”
As the above equation holds for thrust
clearance and gasket thickness is specified as
0.3 mm and thrust clearance as 0.05 to 0.15
mm, shim thickness is calculated by the
following equation.
Shim thickness = (“A” + “B” + 0.3 ) -
(“C” + 0.05 - 0.15)
[Example]
Supposing A, B and C are as follows;
A = 81.35 mm (3.203 in.)
B = 35.70 mm (1.405 in.)
C = 117.05 mm (4.608 in.)
Shim thickness = (81.35 + 35.70 + 0.3) -
(117.05 + 0.05 N 0.15)
= 117.35- 117.10~ 117.20
= 0.25 - 0.15
In this case, use of 0.15 to 0.25 mm (0.006 to
0.009 in) thick shim(s) will ensure specified
thrust clearance which is 0.05 to 0.15 mm
(0.002 to 0.006 in). Therefore 2 pieces of
0.1 mm (0.004 in) thick shim should be
selected in available shims below to satisfy
thickness.
14-16
Fig. 14-48-1

5) When shim thickness is determined, select
proper shim(s) from among the following
shims and use it (them) between input shaft
rear bearing and rear case when matching
center case and rear case.
Available shim0.1, 0.3,0.5 mm
size (thickness)(0.004,0.012,0.020 in.)I
[Output shaft]
Just as with input shaft, take measurements of
“A’ “, “B’ ” and “C’ ” as indicated in Fig.
14-48-1, calculate shim thickness and install
proper shim(s) between output shaft rear bearing
and rear case when matching center case and
rear case.
1. Shim for input shaft2. Shim for output shaft
fig. 14-48-2
14-17
Fig. 14-48-2