1987 SUZUKI GRAND VITARA Service Repair Manual

Pinion-to-gear Tooth Contact Pattern Check and Adjustment
In addition to proper backlash, proper tooth contact must be secured in the mesh of bevel pinion and
gear, so that there will be no “gear noise”coming from the axle and that the hypoid teeth will not be
overstressed in transmitting drive.
After the specified amount of backlash has been secured, check the pinion and gear for tooth contact by
“rolling” contact patterns in a manner consistent with the standard shop practice: use a red lead paste to
paint ten teeth, both drive side and coast side, of the gear, turn the gear back and forth by hand while
holding the pinion in a “braking” manner, and examine the contact patterns in reference to the following
chart:
c
Contact is roughly centered and somewhat
more displaced toward toe than toward heel
on both drive side (concave) and coast
High contact: Contact is on heel (drive side)
and on toe (coast side). This condition means
that the pinion is too far back and must be
brought forward by increasing its shim
thickness used in “mounting distance" adjust-
Low contact: Contact is on toe (drive side)
and on heel (coast side). This condition
means that the pinion is too far out from the
carrier and must be backed away by decreas-
ing its shim thickness.
These contact patterns indicate that the
“offset” of differential carrier is too much or
too little. The remedy is to replace the
carrier with a new one.
16-11

rIContact patterns1Diagnosis, and what to do
These contact patterns, located on toe or heel
on both drive and coast sides, mean that 1)
both pinion and gear are defective, 2) carrier
is not true and square, or 3) gear is not
properly seated on differential case. The
remedy is to replace the defective member.
Irregular patterns: If the pattern is not oval,
it means that bevel gear is defective. High or
low spots on tooth surfaces or on the seat of
bevel gear are the cause of irregular patterns
appearing on some teeth. The remedy is to
replace the pinion and-gear set and, if the seat
is defective, so is differential case.
CAUTION:
When applying red lead paste to teeth, be sure to paint tooth surfaces uniformly. The paste must not
be too dry or too fluid.
16-12

16-5. REASSEMBLY
Reverse disassembly procedure for reassembly,
noting the following.
NOTE:
Bevel pinion and bevel gear are supplied as a
set. Even when only bevel pinion or bevel gear
replacement is necessary, be sure to replace
both as a set.
Differential Pinion Shaft (Shorter)
When installing shaft into differential case and
pinion, insert its “A” side into pinion joint.
Fig. 16-26 @ Pinion joint
A>B (“A” is longer than ‘/Br’.)
Drive Bevel Gear Bolts
Bolts securing bevel gear to differential case are
subject to shear stress since drive is transmitted
by these bolts from gear to case. For this reason,
they are special bolts made from chrome steel
and must never be replaced by common bolts.
When mounting gear onto case, be sure to apply
THREAD LOCK CEMENT SUPER 1333B
(99000-32020) to these bolts before running
them in.
Fig. 16-26-1
Differential Side Bearings
Press-fit these bearings into differential case by
using special tool. Driving the bearing into case
is not permitted.
Fig. 16-27@ Press
@ Special tool (Bearing installer
09940-53111)
16-13

Bevel Pinion Bearings
A press must be used to install two tapered
roller bearings on bevel pinion. Outer races are
press-fitted into the differential carrier and
inner races onto the pinion.
NOTE:
When replacing bevel pinion bearings, check to
ensure that gear side and flange side bearings are
the same marker’s products.
1) For outer race of flange side bearing, use
special tool as shown below.
Fig. 16-28 @ Special tool (Bearing installer
09913-75510)
2) For outer race of gear side bearing, use
special tools.
3) After installing proper bevel pinion shim(s),
press-fit inner race to bevel pinion using
special tools.
@ Special tool (Bearing installer
09925-18010)
Fig. 16-30
@ Special tool (Bearing installer
09940-53111)
4) After installing bevel pinion, spacer, bearings
and universal joint flange to carrier and
carrying out “bevel pinion bearing preload
adjustment”as described previously, cau I k
bevel pinion nut to prevent it from loosening.
Fig. 16-30-1
Fig. 16-29 @ Special tool (Bearing installer
attachment 09924-74510)
@ Special tool (Bearing installer
09926-683 10)
16-14

Side Bearings Caps
When putting on side bearing caps, be sure to
discriminate the right-hand cap from the left-
hand one by referring to match marks scribed
at the time of disassembly.
Then, after carrying out “Bevel gear backlash
adjustment” as described on p. 16-10 torque cap
bolts to specification.
16-6. INSTALLATION
Reverse removal procedure for installation,
noting the following.
Differential
Before installing differential ass’y to axle hous-
ing, clean mating surfaces of differential carrier
and housing and apply sealant to them.
Fig. 16-31 0 Scribed match marks
Fig. 16-32 @ Sealant (SUZUKI BOND NO.
1215 99000-31110)
Front Axle Shaft and Steering Knuckle
For installation them, refer to “Front Suspen-
sion Installation” in SECTION 17 of this manual.
Rear Brake Drum
For installation of rear brake drum, refer to
“Rear Brake Installation” in SECTION 19 of
this manual.
Differential Gear Oil
Refill differential housing with new specified
oil. Refer to “MAINTENANCE SERVICE” in
this section for refill.
Brake Circuit Air Purging
If brake pipe (right & left) was disconnected
from wheel cylinder as in Fig. 16-9-2, make sure
to purge air out of brake circuit. Refer to
section 19. BRAKES for “air purging" operation.
Then check to ensure that joint seam of pipe is
free from oil leak.
16-15

16-7. MAINTENANCE SERVICES
Inspection
Inspect differential and differential housing for
evidence of oil leakage.
Oil level ‘is checked by means of its oil level
plug. Refer to p 1-20 for level inspection,
Fig. 16-33 @ Drain plug
CD Oil level & filler plug
Oil Change
1 ) Remove oil drain plug and drain oil.
2) Reinstall drain plug and tighten it to specified
tightening torque.
3) Remove oil level & filler plug and fill diffe-
rential housing with new specified oil.
Differential oilHypoid gear oil
specificationSAE 8OW-90,75W-80 or 75W-90
OilFront2.0 litres (4.2/3.5 US/Imp pt.)
capacityRear1.5 litres (3.2/2.6 US/Imp pt.)
It is highly recommended to use SAE 75W-90
gear oil.
For viscosity chart, refer to P. 1-20.
16-8. RECOMMENDED TORQUE
SPECIFICATIONS
ITightening torqueI
IFastening partsN.m1 kg-m 11
Side bearing capbolt70- 1007.0-10.051 .O-72.0
Drive bevel gearbolt80- 908.0-9.058.0-66.0
Differential casebolt37-453.7-4.527.0-32.5I
4) Reinstall oil level & filler plug and tighten it
to specified tightening torque.
16-16
Side bearing adjusterlock bolt
Differential carrier bolt
Oil level & filler plug
Oil drain plug

SECTION 17
SUSPENSION
CONTENTS
17-1. FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
17-2. REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-15
17-3. MAINTENANCE SERVICES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
17-4. RECOMMENDED TORQUE SPECIFICATIONS.. . . . . . . . . . . . . . . . 17-26
17-5. FRONT FREE WHEELING HUB (OPTIONAL) . . . . . . . . . . . . . . . . . 17-27
NOTE:
l All suspension fasteners are an important attaching part in that it could affect the
performance of vital parts and systems, and/or could result in major repair expense.
They must be replaced with one of the same part number or with an equivalent part if
replacement becomes necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly to assure
proper retention of this part.
l Never attempt to heat, quench or straighten any suspension part. Replace it with a new
part, or damage to the part may result.
l The leaf spring number or shape shown in this manual may differ from the car being
actually serviced, depending on specification.
17-1

17-1. FRONT SUSPENSION
GENERAL DESCRIPTION
The front suspension consists of the double-acting shock absorbers, stabilizer bar, semi-elliptical leaf
springs, axle housing, etc. as shown below.
The Barfield universal joints are used in the front axle to enable the axle shafts to drive the front wheels
while allowing the wheels to be steered. This type of joint provides for a larger steering angle range and,
what is more important, constant-velocity drive to the wheel.
If a single two-yoke (or Hooke’s) universal joint is used to connect the axle shaft to the wheel on each
side of the front end, the wheels will run with the same speed, but not with the same constant velocity, as
that of the axle shafts when the wheels are turned around their kingpins for steering action. The Barfield
joint transmits drive without varying the angular velocity of drive.
The Barfield joint is enclosed by the knuckle, which is shaped integral with the knuckle arm, and has a
two-piece kingpin, namely, upper and lower kingpins.
The end of the dead axle sleeve is in the shape of dish. This dish is rotatably fitted into the knuckle
structure to form a flexible connection, the sliding clearance between the two being sealed with a felt
packing (against road dust and mud) and also with an oil seal (against the oil inside). The upper and lower
kingpins, bolted to the knuckle extend into the knuckle and, inside, are held by the dish-like inner case
through tapered roller bearings.
BushWasher
Front axle housing
Oil seal cover
retainer ISteeringLn,,rlrlo
Front wheel hub
Front wheel bearing
1\;lEkl bearing nutFront wheelbearina
Shacklebush
outerplateASta ilizer\drive flange
nut
Fig. 17-1-1
17-2