1999 SUZUKI GRAND VITARA Gear oil

DIFFERENTIAL (REAR) 7F-3
On-Vehicle Service
1. Universal joint flange 9. Differential carrier assembly 17. Bearing adjuster 25. Bolt
2. Hypoid gear set 10. Differential pinion 18. Lock plate 26. Bolt
3. Bevel pinion spacer
Apply thread lock cement
99000-32110 referring to
“DIFFERENTIAL CASE” in
this section.11. Differential gear 19. Pinion shaft No.2 27. Differential case screw :
Apply thread lock
cement 99000-32110 to
thread part of bolt.
4. Shim 12. Pinion shaft No.1 20. Pinion joint Do not reuse.
5. Rear bearing 13. Differential left case 21. Spring washer Tightening torque
6. Front bearing 14. Differential right case 22. Washer Apply differential oil.
7. Oil seal :
Apply grease 99000-25010
to oil seal lip.15. Thrust washer 23. Bevel gear bolt :
Apply thread lock
cement 99000-32110
to thread part of bolt.
8. Flange nut :
After tightening nut so as
rotation torque of bevel pin-
ion shaft to be in specified
value, caulk nut securely.16. Differential side bearing 24. Bolt

7F-4 DIFFERENTIAL (REAR)
Precaution for Maintenance Service
•When having driven through water, check immediately if
water has entered (if so, oil is cloudy). Water mixed oil must
be changed at once.
•Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status of
breather hoses.
Differential Gear Oil Change
1) Before oil change or inspection, be sure to stop engine and
lift up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain plug (3) and level/filler plugs (2) to specification.
“A” : Sealant 99000-31110
Tightening torque
Differential oil level/filler plug (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil drain plug (b) :
28 N·m (2.8 kg-m, 20.5 lb-ft)
Hypoid gear oil :
API GL-5, SAE 75W-85, 80W-90 or 90
Oil capacity :
2.5 liters (5.3/4.4 US/Imp. pt.) NOTE:
Hypoid gear oil must be used for differential.
It is highly recommended to use SAE 80W-90 viscosity.
1. Breather hose

7F-6 DIFFERENTIAL (REAR)
3) Install propeller shaft to joint flange aligning match marks
and torque flange nuts to specification. Apply thread lock
cement to thread part of bolt if reused.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft flange nuts (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
4) Install right and left rear axle shafts and drums.
(Refer to “REAR AXLE INSTALLATION” of Section 3E and
rear brake drum installation of Section 5.)
5) Install wheels.
6) Fill hypoid gear oil as specified and tighten plug to specifica-
tion.
7) Lower lift.
Unit Repair
Disassembling Unit
1) Hold differential assembly securely and put identification
marks on differential side bearing caps (6).
2) Take off differential side bearing lock plates (4) and differen-
tial side bearing caps (6) by removing their bolts and then
take out bearing adjusters (5), side bearing outer races and
drive bevel gear with differential case.
3) Remove drive bevel gear (hypoid gear), differential gears,
differential pinions and pinion shafts.
a) With aluminum plates (2) placed on vise first, grip differen-
tial case with it and remove drive bevel gear (hypoid gear)
(3) by removing its bolts (1).
1. Differential carrier
2. Drive bevel gear assembly
3. Differential case
A: Identification mark
1
3
2

DIFFERENTIAL (REAR) 7F-9
6) Using a hammer and brass bar (1), drive out front bearing
outer race with bearing (2) and oil seal (3).
7) Drive out rear bearing outer race in the same way as in the
step 6).
Component Inspection
•Check companion flange for wear or damage.
•Check bearings for wear or discoloration.
•Check differential carrier for cracks.
•Check drive bevel pinion and drive bevel gear for wear or cracks.
•Check differential gears, pinions and pinion shafts for wear or damage.
•Check differential gear spline for wear or damage.
Sub-Assembly Adjustment and Reassembly
Judging from faulty conditions noted before disassembly and
what is found through visual check of bearing and gear tooth etc.
after disassembly, prepare replacing parts and proceed to reas-
sembly according to procedures as described below.
CAUTION:
Drive bevel gear and pinion must be replaced as a set
when either replacement becomes necessary.
When replacing taper roller bearing, replace as inner
race & outer race assembly.

7F-10 DIFFERENTIAL (REAR)
Differential carrier
For press-fitting drive bevel pinion bearing outer races, use spe-
cial tools as shown in the figure.
Special tool
(A) : 09924-74510
(B) : 09926-68310
(C) : 09913-75510
Differential case
1) After applying differential oil to differential gear (4), pinions
(5), pinion shafts (6), thrust washer (2) and spring washer
(1), install them in differential right case (3).
For correct installing direction of thrust washer (2) and spring
washer (1), refer to the figure.
2) When installing pinion shaft No.2 (2) (shorter) into differential
case and pinion, insert its “a” side into pinion joint (1).
3) Check differential pinion gear (1) for smooth rotation.
1. Differential carrier
NOTE:
“a” is longer than “b”. (“a” > “b”)
1
2
a
b
1

DIFFERENTIAL (REAR) 7F-21
10) Upon completion of gear tooth contact check in Step 9),
caulk flange nut (2) with caulking tool (1) and hammer.
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Differential oil level/filler plug 50 5.0 36.5
Differential oil drain plug 28 2.8 20.5
Propeller shaft flange nuts 60 6.0 43.5
Differential carrier bolts 55 5.5 40.0
Bevel gear bolts 105 10.5 76.0
Bearing cap bolts 85 8.5 61.5
Lock plate bolts 12 1.2 9.0
Differential case screws 9 0.9 6.5
MaterialRecommended SUZUKI product
(Part Number)Use
Thread lock cement THREAD LOCK CEMENT
SUPER 1322
(99000-32110)Bevel gear bolts
Differential case bolts
Bevel gear mating surface
Propeller shaft flange bolt
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Rear differential drain plug
Mating surface of differential housing
Mating surface of rear axle housing