1987 SUZUKI GRAND VITARA Service Repair Manual

16-2. REMOVAL
1. Loosen, but do not remove, wheel nuts of
front or rear wheels, and raise car off the
2.
3.
floor by jacking.
Rest car steady on safety stands.
Drain out oil in differential housing by
loosening drain plug.
Remove wheel nuts and take off wheels,
front or rear. Each wheel has five wheel nuts.
For Front Differential
After taking down front wheels, remove disc
brake caliper with carrier.
NOTE:
Hang removed caliper with a wire hook or the
like so as to prevent brake hose from bending
and twisting excessively or being pulled.
Don’t operate brake pedal with caliper removed.
Fig. 16-2
Fig. 16-3
At each tie rod end, remove nut and disconnect
the end from steering knuckle using special tool
@
Fig. 16-4@ Special tool (Tie rod end remover
099 13-652 10)
Remove 8 oil seal cover securing bolts. From
steering knuckle, take off felt pad, oil seal and
seal retainer.
Fig. 16-5
Remove top and bottom kingpins from knuckle
by removing 4 bolts securing each pin.
NOTE:
The removed top and bottom kingpins must be
kept separated so as to prevent an error when
putting them back in their place in reassembly.
16-3

Fig. 16-6Fig. 16-8
Draw out live axle shaft from axle housing.
NOTE:
At this time, lower kingpin bearing sometimes
falls off. So remove bearing while pulling off
knuckle gradually.
Fig. 16-7
At differential housing, disconnect propeller
shaft by removing bolts securing flange yoke to
companion flange. Remove 8 bolts holding fast
differential carrier case to housing, and take
down carrier assembly.
For Rear Differential
After taking down rear wheels, remove brake
drums by using special tools.
NOTE:
Before removing brake drum, check to ensure
that parking brake lever is not pulled up.
To increase clearance between brake shoe and
brake drum, remove parking brake shoe lever
return spring @ and disconnect parking brake
cable joint @ from parking brake shoe lever 0.
Remove parking brake shoe lever stopper plate.
1. Parking brake shoe leverreturn spring2. Parking brake shoe lever 3. Parking brake cable joint
4. Pin
5. Clip
6. Brake back plate
Fig. 16-9
16-4

Fig. 16-19-1 @ Special tool (Brake drum remover
09943-355 7 1)
Fig. 16-10 @ Special tool (Rear axle remover
09922-66010)
@ Special tool (Sliding hammer@ Special tool (Sliding hammer
09942- 15510)09942-15510)
Disconnect brake pipe from wheel cylinder.
Have a small plug ready for use when disconnect-
ing pipe. As pipe comes off the wheel cylinder,
plug the pipe to prevent brake fluid from
leaking out.
And remove 4 brake backing plate securing
bolts.
Fig. 16-9-2 @ Plug
Using special tools indicated below, draw out
each axle shaft with brake backing plate.
Disconnect propeller shaft as in the case of front
axle, and detach and take down differential
carrier case from housing by removing 8 bolts.
Fig. 16-11
16-5

16-3. DISASSEMBLY
Lock flange immovable by using special tool,
and remove nut from the end of bevel pinion
shank.
Fig. 16-12 @ Special tool (Rotor holder 09930-
40 113)
Scribe marks on each cap bolted to the saddle
portion of carrier case and holding down the
side bearing. The marks are to identify caps.
This means that there are right and left caps, so
identified and so handled at the time of reas-
sembly.
Fig. 16-13 @ Scribed match marks
At each side, loosen bolts on bearing adjuster
stopper,remove bearing cap securing bolts,
and take off cap. Lift differential case assembly,
complete with bevel gear, off the carrier.
Fig. 16-14
Remove 10 bolts securing bevel gear to diffe-
rential case, and separate gear from case.
Fig. 16-15
There are 8 bolts fastening two differential
case halves together. Remove these bolts to
sever right-hand case half from left-hand one,
and take off right-hand one.
Fig. 16-16 @ Special tool (Rotor holder
09930-40 113)
16-6

Remove side gears, differential pinions and
thrust washers.
Fig. 16-17
Using special tools indicated below, extract
side bearing from each differential case half.
Fig.16-18@ Special tool (Bearing puller
09913-60910)
@ SptCal tool (Side bearing removing jig
099 13-85230)
Using puller and hydraulic press, remove inner
race of bevel pinion bearing.
16-4. INSPECTION AND ADJUSTMENT
OF COMPONENTS
Side Gear Thrust Play
To check thrust play, assemble differential
gearing and case, as shown in Fig. 16-19, fasten-
ing together two case halves by tightening
securing bolts to prescribed torque. By compar-
ing thrust play reading, taken as shown in Fig.
16-19, against thrust play indicated below,
increase or decrease total thickness of thrust
washers, which are located in two places, that
is, on the inner side of each case half.
Side gear thrust play0.12 - 0.37 mm
specification(0.005 - 0.014 in)
Available thrust washer
sizes (thickness)
0.9, 1.O, 1.1 & 1.2 mm
(0.035,0.039,0.043 &
0.047 in)
Fig. 16-19
Fig. 16-18-1 0 Hydraulic press@ Puller
16-7

Determination of Shim Thickness for Bevel
Pinion
Thickness of shims to be used on the bevel
pinion varies from one vehicle to another on
account of factors involved in machining and
assembling. Thus, for each vehicle, the thick-
ness of shims necessary for locating pinion in
correct position (for producing a proper backlash
in the mesh between pinion and gear) must be
determined anew at the time of reassembly.
In order to facilitate this determination, a 2-
piece dummy tool (special tool) is made avail-
able. Following procedure is based on use of this
tool and supposes that pinion dummy (one of
the two pieces) is set in carrier, without any
shims, as shown in Fig. 16-20.
Fig. 16-20 @ Special tool (Bevel pinion
mounting dummy 09926-78310)
l Set dial indicator on dummy, letting the
indicator spindle protrude 5 to 6 mm from
the bottom of dummy as shown in Fig.
16-21-1.
5-6mm
(0.197 - 0.236 in)

16-8
2) Feed dummy pinion with bearings into the
carrier,positioning it properly, and install
joint flange.
And then tighten bevel pinion nut until
specified starting torque of bevel pinion is
obtained. Refer to item 2) and 3) of “Bevel
Pinion Bearing Preload Adjustment” describ-
ed on next page.
NOTE:
In this case, fit only bearings to bevel pinion.
Don’t fit spacer.
3) Rest dummy with dial indicator on carrier
and pinion dummy, and set dial indicator to
zero.
Fig. 16-21-2 1. Dummy 2. Pinion dummy 3. Dial indicator
4) Referring to Fig. 16-21-3, note that three
dimensions are involved: “a” “b” and “c”.
The value of “b” is unknown, and is to be
determined now for calculating the required
thickness of shims. The values of “a” and
“c” are given: the sum, “a” +“c”, is 94 mm,
which is indicated on the dummy tool.
Fig. 16-21-3
Fig. 16-21-1

Rest dummy with dial indicator on surface
plate, and the dial indicator pointer may have
deflected from “0” mark to show a certain
value; read this value, which is “b”.
SURFACE PLATE
Fig. 16-21-4
Add this reading to 94 mm (= “a” + “c”) and,
from the sum, subtract the value marked on
bevel pinion. The remainder is required shim
thickness: (94+“b”) - marked value = required
shim thickness1
Fig. 16-22 I. Marked value
5)Shim stock is available in twelve selective L
thicknesses. Select one or two shim(s) from
the below to obtain the closest thickness to
above required thickness, and insert selected
shim piece(s) into clearance indicated as
Fig. 16-21-3 0.
1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18,
Bevel Pinion Bearing Preload Adjustment
The bevel pinion, as installed in normal manner
in carrier, is required to offer a certain torque
resistance when checked by using prescribed
preload adjuster (special tool @ ) as shown in
Fig. 16-23. This resistance is a “preload,”
which is due to the tighteness of the two tapered
roller bearings by which the pinion is held in the
carrier. And this tighteness is determined prima-
rily by tightening torque of bevel pinion nut.
Adjust preload of bevel pinion bearings as
follows.
1) Install pinion bearings, spacer, bevel pinion,
oil seal and universal joint flange to diffe-
rential carrier.
At this time, be sure to apply gear oil to
bearings lightly and grease to oil seal lip.
2) Tighten bevel pinion nut by hand, and install
special tool to universal joint flange.
3) After turning pinion several times, tighten
pinion nut gradually, while checking pinion
starting torque with spring balance, and stop
tightening when starting torque reaches
specification given below.
4) Caulk bevel pinion nut to prevent it from
loosening.
NOTE:
Bevel pinion bearing preload is adjusted by
tightening bevel pinion nut to crush spacer.
Therefore, be sure to use a new spacer for
adjustment and tighten pinion nut step by step
and check for starting torque (preload) as often
as tightening to prevent over crushing of spacer.
If exceeds specification given below during
adjustment, replace spacer and repeat preload
adjustment procedure. Attempt to decrease
starting torque (preload) by loosening pinion
nut will not do.
The below data are not tightening torque of
pinion nut but pinion bearing preload.
Fig. 16-23 @ Spring balance
@ Special tool (Differential gear preload
adjuster 09922-75221)
16-9

Bevel Gear Backlash Adjustment
Backlash between bevel gear and pinion is
checked as shown in Fig. 16-24. Note that
differential case assembly is mounted in the
normal manner, and fastened down by tighten-
ing the side bearing cap bolts to 1.0 - 2.0 kg-m
(7.5 - 14.0 lb-ft). At this time, screw in each
adjuster till it contacts bearing outer race so that
outer race is prevented from inclining. The dial
indicator spindle is pointed squarely to “heel”
on drive side (convex side) of gear tooth. Hold
bevel pinion rigidly, and turn gear back and
forth.
The dial indicator reading, which is bevel Qear
backlash, must be within this range:
I
Bevel gear backlash0.10 - 0.15 mm
(0.004 - 0.006 in.)
Fig. 16-24
To increase or decrease backlash for adjustment,
displace bevel gear toward or away from pinion
by running in one adjuster and running out the
other adjuster by equal amount.
Turning the adjuster one notch changes backlash
by about 0.05 mm (0.002 in.).
CAUTION:
l Adjust preload on side bearing during
back-lash adjustment: mount special tool
on drive bevel pinion as shown in Fig.
16-23 and measure using spring balance
0. If reading at the instant bevel gear
starts moving is within the range given
below, side bearing preload is acceptable.
Referring to the graph, for example,
when the drive bevel pinion bearing
preload measured as shown in Fig. 16-
23 is 2.6 kg (5.73 lb), drive bevel pinion
bearing preload (kg) + bevel gear side
bearing preload (kg) should be 2.8 - 3.2
kg (6.17 - 7.05 lb).
l Upon completion of this adjustment, be
sure to tighten bearing cap bolts to 7.0 -
10.0 kg-m or 51.0 - 72.0 Ibft.
?’
1.61.92.02.12.22.32.42.52.62.72.62.93.03.13.23.33.4(Kg)
Drive bevel pinion bearing starting torque (preload)
Fig. 16-25 @ Special tool (Rotor holder
16-10