1987 SUZUKI GRAND VITARA Service Repair Manual

Rear Case
1) Install oil seal in rear case and apply grease
to oil seal lip.
Center Case
1) Install input shaft front bearing circlip and
oil seal in center case.
Snap ring pliers @ : (09900~6108)
Fig. 14-49
Fig. 14-51
2) Install counter shaft thrust washer to rear
case, bringing its face without depressions
against case and fit its bent portion securely
into groove in case.
NOTE:
Apply ample amount of grease to both surfaces
of washer so as to lubricate sliding surfaces and
prevent washer from moving out of place or
slipping off.
Fig. 14-50
2) Install input shaft to center case.
Fig. 14-52
3) After greasing 0 ring on counter shaft,
insert shaft into center case and secure
shaft with lock plate and bolt.
Fig. 14-53
Fig. 14-50
14-18
Fig. 14-53
Fig. 14-52

4) Install the counter shaft thrust washer to
center case. For installation, apply ample
amount of grease to both faces of the washer
so as to lubricate sliding surfaces and prevent
it from moving out of place or slipping off
and bring its face without depressions against
center case, and fit its bent portion into
groove in case securely.
Fig. 14-54
5) Install needle roller bearings, spacer and
counter gear on counter shaft.
Fig. 14-55
6) Install output shaft assembly to center case.
Fig. 14-56
7) When installing front drive shift shaft and
reduction shift shaft in center case, install
spring 0, ball 0, shaft 0, ball @, shaft
0, ball 8, spring 0 and plug 8. in that
order.
d 18-3ON.m
Fig. 14-57(1.8 - 3.0 kg-m 1(13.5 - 21.5 lb-ft)
8) Fit forks on shift shafts and lock them
with spring pins. Forks should be fitted in
correct direction according to below figure.
Fig. 14-58
14-19
Fig. 14-54
Fig. 14-55
Fig. 14-58
Fig. 14-57
Fig. 14-56
14-19

Center and Rear Cases
1) Check center case (or rear case) to ensure
that it is provided with 2 dowel pins 0.
Fig. 14-59
2) Put gasket on center case. Bring rear case
and center case into match and apply
uniform force gradually all around rear case
with a plastic hammer. Tighten center case
securing bolts to specified torque.
NOTE:
l Matching must be made carefully so as not to
move countershaft thrust washers out of place.
l Be sure to install shims determined in previ-
ous item“Shim Adjustment of Input and
Output Shafts”between input shaft rear
bearing and rear case and between output
shaft rear bearing and rear case.
Fig. 14-61
Fig. 14-62
3) Apply grease to output front shaft rear
bearing.
Fig. 14-60
Fig. 14-63
14-20

Front Case
1) Install bearing, circlip and oil seal to front
case. Apply grease to oil seal lip and install
output front shaft using bearing installer
(special tool).
Bearing installer (A) : (09913-76010)
Fig. 14-64
2) Put gasket on center case.
3) Check front case to ensure that it is provided
with 2 dowel pins.
Fig. 14-65
4) Install front case to center case.
Fig. 14-66
5) When installing speedometer driven gear
and its gear case in rear case, apply grease to
0 ring and oil seal lip, and align bolt holes
in rear case and driven gear case.
Fig. 14-67
6) Install 4WD ball and switch. Then clamp
switch lead wire properly.
/1.6 - 2.3 kgm
Fig. 14-68 (12.0 - 16.5 lb-h)
14-21

7) Install propeller shaft flanges and tighten
nuts to specified torque and talk the nuts.
8) Upon completion of entire assembly work,
install transfer in chassis body in reverse
sequence of removal. Pour gear oil into
transfer gear box.
Refer to information given in next oil and
oil capacity for oil to be used and specified
amount.
NOTE:
When installing oil filler and drain plugs to
transfer case, apply sealant (SUZUKI BOND
No.1215, 99000-31110) to thread part of plug.
14-9. MAINTENANCE SERVICES
Oil Level
Oil level must be checked with car held in
horizontal position in both front to rear and side
to side directions.
Oil level plug and oil filler plug are one and the
same as shown in figure.
If oil flows out of filler plug hole or if oil level is
found up to hole when plug is removed, amount
of oil is appropriate. Replenish oil if noted as
insufficient.
Oil and Oil Capacity
Whenever car is lifted up for any service includ-
ing oil change,make sure to check around
transfer gear box for oil leakage. Correct defects,
if any, and change or refill oil.
Transfer oil capacity0.8 litre (1.7/l .4 US/Imp. pt)
Transfer oilGear oil SAE 8OW-90,
specification75W-80 or 75W-90
It is highly recommended to use SAE 75W-90
gear oil.
For viscosity chart, refer to P. 1-20.
@ : Oil drain plug
Fig. 14-70@ : Oil filler & level plug
14-22

14-10. TIGHTENING TORQUE
Counter shaft lock
Universaljoint flange
Oil filler and drain
plug
Cross joint bolt & nut
Transfer mounting nut
Transfer mounting
bracket bolt
Universal joint
flange nut
Counter shaft lock
plate bolt
Center case bolt
Front case bolt
Fastening parts
14-23

SECTION 15
PROPELLER SHAFTS
CONTENTS
15-1. GENERAL DESCRIPTION..................................15-2
15-2. REMOVAL..............................................15-3
15-3. INSTALLATION.......................................... 15-3
15-4. MAINTENANCE SERVICES.................................15-4
15-5. TIGHTENING TORQUE....................................15-5
15-6. DISASSEMBLY..........................................15-6
15-7. REASSEMBLY.......................................... 15-7
15-1

151. GENERAL DESCRIPTION
These automobiles, covered in this manual are four-wheel drive machines and, as such, use three propeller
shafts designated as No. 1, No. 2 and No. 3.
No, 1 propeller shaft transmits drive from the transmission to the transfer gear box. No. 2 shaft and No. 3
shaft extend from the transfer gear box, the former driving the front axle and the latter the rear axle.
The cross spider in each universal joint is fitted with four needle roller bearings.
From
TQ transfer
transmission casaTo transfar casa
Propeller shaft No. 2
To rear differential
To front differential
To transfer case
15-2
Fig. 15-1