1999 SUZUKI GRAND VITARA plug gear

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Differential side joint
2. Tire lever
3. Front differential assembly
1. Oil seal 2
1
4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
REMOVAL (RIGHT SIDE)
1) Hoist vehicle and remove wheel.
2) Drain differential gear oil.
3) Remove axle shaft drive flange.
4) Remove circlip and front spindle thrust washer.
5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and
9) to 14) of item COIL SPRING REMOVAL in Section 3D.
6) Remove drive shaft assembly.
To detach snap ring fitted on the spline of differential side joint
(inboard joint) from differential side gear, pull inboard joint by us-
ing a tire lever.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
7) Remove drive shaft thrust washer (to vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
7A
MANUAL TRANSMISSION (TYPE 1) 7A-1
TYPE 1
GENERAL DESCRIPTION7A- 1 . . . . . . . . . . . . . .
DIAGNOSIS7A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A- 3 . . . . . . . . . . . . . . . .
Gear Oil 7A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A- 4. . . . . . . . . . . . . . . . . . .
Switches 7A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A- 8. . . . . . . . . . . . . . . .
Dismounting of Trans. Unit 7A- 9. . . . . . . . . . . . .
Remounting of Trans. Unit 7A-12. . . . . . . . . . . . . Extension Case (2WD MODEL) 7A-13. . . . . . . .
Extension Case Oil Seal
(2WD MODEL) 7A-13. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A-14 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A-14 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A-14 . . . . . .
SPECIAL TOOL7A-14 . . . . . . . . . . . . . . . . . . . . . . .
As the aluminum case is sealed with liquid type gas-
ket, it is necessary to use genuine sealant or its equiv-
alent on its mating surfaces when reassembling it.
Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and
tightening over or below the specified torque should
be avoided.
The description under ON-VEHICLE SERVICE in this
section covers a part of the TYPE 2 manual transmis-
sion and the transfer. The transfer is next to the trans-
mission as well, but their gear boxes are independent
and each of them has its own drain and level / filler
plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A
MANUAL TRANSMISSION
(TYPE 1)
CONTENTS
GENERAL DESCRIPTION
The manual transmission consists of the input shaft,
main shaft, countershaft and reverse gear which are
installed in the aluminum case. Its gears are of for-
ward five speeds in synchro mesh and reverse one
speed in constant mesh system.
The main shaft gears are held by the needle bearings
and on them the synchronizer rings and synchronizer
sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.

YH4
GRAND
VITARA
Viscosity chart
SAE
1. Reverse idle gear shaft bolt
(DO NOT LOOSEN IT)
MANUAL TRANSMISSION (TYPE 1) 7A-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

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.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 1.5 liters (3.2 / 2.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to its thread.
CAUTION:

Transmission oil must not be poured through gear shift
control lever part.

Do not loosen or remove reverse idle gear shaft bolt.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
7A1
MANUAL TRANSMISSION (TYPE 2) 7A1-1
TYPE 2
GENERAL DESCRIPTION7A1-1 . . . . . . . . . . . . . .
DIAGNOSIS7A1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A1-3 . . . . . . . . . . . . . . . .
Gear Oil 7A1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A1-4. . . . . . . . . . . . . . . . . . .
Switches 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A1-4. . . . . . . . . . . . . . . . Dismounting / Remounting of
Trans. Unit 7A1-4. . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A1-4 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A1-5 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A1-5 . . . . . .
The manual transmission consists of the input shaft,
main shaft, counter shaft and reverse gear which are
installed in the aluminum and castings cases. Its
gears are of forward five speeds in synchro mesh and
reverse one speed in sliding idler gear arrangement
system.
The main shaft gears are held by the needle bear-
ings and on them the synchronizer rings and syn-
chronizer sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.As the aluminum and castings cases are sealed with
liquid type gasket, it is necessary to use genuine seal-
ant or its equivalent on its mating surfaces when reas-
sembling them. Also, the case fastening bolts must be
tightened to specified torque by means of the torque
wrench and tightening over or below the specified
torque should be avoided.
The description under ON-VEHICLE SERVICE in this
section covers the transfer partially which is next to
the transmission as well, but their gear boxes are in-
dependent and each of them has its own drain and
level / filler plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A1
MANUAL TRANSMISSION
(TYPE 2)
CONTENTS
GENERAL DESCRIPTION

YH4
GRAND
VITARA
Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:

It is highly recommended to use SAE 75W-90 gear oil.

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.

If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
7A1-4 MANUAL TRANSMISSION (TYPE 2)
SHIFT CONTROL LEVERS
Refer to SECTION 7A in this manual.
SWITCHES
Refer to SECTION 7A in this manual.
ENGINE REAR MOUNTING
Refer to SECTION 7A in this manual.
DISMOUNTING / REMOUNTING OF TRANS.
UNIT
Refer to the same item in SECTION 7A ªMANUAL TRANSMIS-
SIONº.
For tightening torque of filler and level / drain plug, refer to ªGear Oil
Inspection and Changeº of ªON-VEHICLE SERVICEº in this sec-
tion.
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.

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-16 DIFFERENTIAL (FRONT)
(a)
(a)
(a)
1. Drive shaft joint R
2. Differential housing3. Transmission jack
4. Screw driver
8) Using 2 large screwdrivers as levers, pull out right side drive
shaft joint from differential and dismount housing assembly from
vehicle.
CAUTION:
During above work, use care not to cause damage to
drive shaft boot.
REMOUNTING
For remounting, reverse dismounting procedure and use following
tightening torque.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
After tightening all fasteners properly, fill hypoid gear oil as speci-
fied and check tightening of plugs with specification.