1999 SUZUKI GRAND VITARA tightening torque

YH4
GRAND
VITARA
7D
TRANSFER 7D-1
The aluminum transfer case directly connected to the
back of the transmission contains the input gear,
countershaft & gear, output rear shaft, output low gear
and output front shaft (for front drive) connected by
way of the hyvo-chain.
The transfer has such a selective mechanism as to
enable the shift control lever to make selection of high
speed (direct connection with transmission output:
main shaft), low speed (speed reduction by input
gear, counter gear and output low gear) or neutral by
way of the reduction sleeve located between input
gear and output low gear, and selection of two-wheel-
drive (high speed only) or four-wheel-drive (high or
low speed) by way of the front drive clutch sleeve lo-cated at the center of the output rear shaft. Also, with
a synchronizer installed to the front drive clutch, it is
possible to change the drive mode between 2WD
(high speed only) and 4WD (high speed only) even
while running.
The front drive shift fork has an auxiliary spring to
make a smooth shift from 4H to 2H possible.
The case has an oil gutter and a plate at synchronizer
to provide proper lubrication even under the strict
conditions of use.
WARNING:
For towing the vehicle for the purpose of repair or
the like, follow the towing instructions in OWN-
ER'S MANUAL.
SECTION 7D
TRANSFER
CONTENTS
GENERAL DESCRIPTION7D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Oil Seals7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Driven Gear7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Assembly7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7D-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
1. Match mark
1. Transfer rear case
2. Oil seal
ªAº
ªBº
TRANSFER 7D-3
ON-VEHICLE SERVICE
GEAR OIL
Refer to ªON-VEHICLE SERVICEº of Section 7A or 7A1.
TRANSFER OIL SEALS
REAR CASE OIL SEAL
1) Lift up vehicle horizontally.
2) Give match marks on joint flange and propeller shaft as shown
in figure.
3) Remove 4 bolts from rear propeller shaft flange and remove pro-
peller shaft.
4) Using screwdriver, remove oil seal.
5) Using special tool(A) and plastic hammer, pressfit new oil seal
up to case surface. Be sure to apply grease to oil seal lip.
ªAº: Grease 99000-25010
Special Tool
(A): 09940-53111
6) Clean and inspect sliding portion of propeller shaft front end
(where oil seal contacts) before installation and if even small
dent or scratch exists, correct and clean it again.
Then apply grease inside splines of propeller shaft.
ªBº: Grease 99000-25010
7) Install propeller shaft and torque universal joint flange bolts to
specification.
CAUTION:
Be sure to use only specified bolts, nuts and lock wash-
ers for universal joint flange.
Tightening Torque:
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CENTER CASE OIL SEAL (Front side)
In addition to the procedure for rear case oil seal, it is necessary to
drain and refill gear oil of transfer. Refer to Section 7A ªON-VE-
HICLE SERVICEº for oil specification.

YH4
GRAND
VITARA
1. Speed sensor assembly
2. Transfer
7D-4 TRANSFER
SPEEDOMETER DRIVEN GEAR
REMOVAL
1) Lift up vehicle horizontally or rear up.
2) Disconnect speed sensor coupler at transfer case.
3) Remove bolt and take off speed sensor from transfer.
INSTALLATION
1) Make sure that O-ring and speed sensor have not been dam-
aged.
2) Inspect speedometer driven gear for abnormal wear of gear
teeth or bend of shaft portion and replace it if necessary.
3) Make sure its smooth rotation.
4) Install speed sensor assembly to transfer and connect coupler
as it was.
Tightening Torque
(a): 6 N
.m (0.6 kg-m, 4.5 lb-ft)
ENGINE REAR MOUNTING
Refer to ªON-VEHICLE SERVICEº of Section 7A.

YH4
GRAND
VITARA
1. Bolt
2. Transfer assembly
1. Bolt
2. Engine rear mounting3. Transfer assembly
1. Bolt
2. Transfer assembly
3. Transmission jack
7D-6 TRANSFER
IN CABIN
Remove gear shift lever case and then remove transfer center case
bolt.
ON LIFT
1) Remove transfer mounting (engine rear mounting) by removing
bolts.
2) Apply transmission jack to transfer to support it.
3) Remove couplers for 4WD / 4WD-LOW switches lead.
4) Remove transfer front case bolts.
5) With transfer assembly supported with transmission jack, slide
it rearward and when it is apart from transmission, lower it.
REMOUNTING
For remounting, reverse dismounting procedure described above,
noting following.

Be sure to use specified torque for tightening.

Clamp wiring and breather hose securely.

Clamp shift lever boot securely.

Fill specified gear oil by specified amount.

Connect battery and check for function.

YH4
GRAND
VITARA
TRANSFER 7D-7
09940-53111
Bearing installer
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Oil filler / level and drain plugs232.317.0
Engine rear mounting bolts505.036.5
Universal joint flange bolts505.036.5
Speed sensor bolt60.64.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)

Oil seal lips and O-rings.

Splines of propeller shaft.

Select return system.

Shift control lever.
SPECIAL TOOL

YH4
GRAND
VITARA
7E
DIFFERENTIAL (FRONT) 7E-1
The differential assembly using a hypoid bevel pinion
and gear is installed to the front axle.
4WD control system controls drive force to be trans-
mitted to front axles or not. The reduction ratio varies
depending on transmission or engine type.The differential assembly is decisive in that the drive
power is concentrated there. Therefore, use of genu-
ine parts and specified torque is compulsory. Further,
because of sliding tooth meshing with high pressure
between bevel pinion and gear, it is mandatory to lu-
bricate them by hypoid gear oil.
SECTION 7E
DIFFERENTIAL (FRONT)
CONTENTS
GENERAL DESCRIPTION7E- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD CONTROL SYSTEM7E- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS TABLE7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Control System Diagnostic Flow Table 7E- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD CONTROL CIRCUIT INSPECTION 7E- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil Change7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION7E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Control System7E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator7E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Pump Assembly7E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION 7E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Mountings7E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING7E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOUNTING7E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-9
Viscosity chart SAE
Temperature
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter 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.
Gear Oil Change
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W ± 90 viscosity.
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, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified be-
low (roughly up to level hole).
4) Apply sealant to thread of drain plug (b) and torque plugs to
specification.
Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W ± 85, 90 or 80W ± 90
For oil viscosity, refer to left chart.
Oil capacity: 1.0 liters (2.1 / 1.8 US / lmp. pt)

YH4
GRAND
VITARA
7E-12 DIFFERENTIAL (FRONT)
1. Pump assembly
Air Pump Assembly
Removal / Installation
1) Disconnect air hoses and coupler from air pump assembly.
2) Remove pump assembly by removing bolts.
3) Reverse removal procedure for installation.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
Inspection
1) Install special tool, voltmeter and battery to pump assembly as
shown in figure.
2) Tighten adjusting screw of special tool as far as it stops and
close its air check side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
3) Check that motor starts to run (a sound can be heard) when bat-
tery is connected and it stops when specified pressure is ob-
tained.
Check also for air leakage.
Specified pressure: 30.0 ± 45.0 kPa
(0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that value indicated on voltmeter is within specification
shown below.
When motor is running: 0 ± 1 V
When motor has stopped running: 10 ± 14 V
CAUTION:
Do not run motor more than 10 seconds continuously to
prevent motor breakage.