2001 SUZUKI GRAND VITARA Lock

AUTOMATIC TRANSMISSION (4 A/T) 7B1-59
•Tighten TCC (lock-up) solenoid valve bolt to specified
torque.
Tightening torque
TCC solenoid valve bolt :
5.5 N·m (0.55 kg-m, 4.0 lb-ft)
•Tighten pressure relief valve bolt to specified torque.
Tightening torque
Pressure relief valve bolt :
5.5 N·m (0.55 kg-m, 4.0 lb-ft)
•Tighten lower valve body plate (1), TCC (lock-up) control
valve plate (2) flange bolt to specified torque.
Tightening torque
Lower valve body and TCC control valve Plate bolts :
5.5 N·m (0.55 kg-m, 4.0 lb-ft)
Unit Assembly
1) Apply A/T fluid to new O-ring and spring and install them to
accumulator piston and install accumulator piston to trans-
mission case.
1. Solenoid valve No. 2 (TCC solenoid valve)
2. O-ring
4. Upper spring

7B1-60 AUTOMATIC TRANSMISSION (4 A/T)
Accumulator piston and spring specification :
Tightening Torque Specification
Used forPiston outer
diameter “a”Spring free length “b”
Direct clutch accumulator (2)31.80 – 31.85 mm
(1.252 – 1.254 in.)Upper spring 43.56 mm (1.715 in.)
Lower spring 30.00 mm (1.181 in.)
Forward clutch accumulator (1)31.80 – 31.85 mm
(1.252 – 1.254 in.)Upper spring 57.18 mm (2.251 in.)
Lower spring 30.50 mm (1.201 in.)
Second brake accumulator (3)34.80 – 34.85 mm
(1.370 – 1.372 in.)Upper spring 56.16 mm (2.211 in.)
Lower spring 18.5 mm (0.728 in.)
Fastening partTightening torque
Nm kg-m lb-ft
Automatic transmission fluid drain plug 23 2.3 17.0
Transfer oil level/filler and drain plugs 23 2.3 17.0
Transmission case plug 17 1.7 12.5
Manual select lever nut 13 1.3 9.5
Manual select cable nut 7 0.7 5.5
Manual selector assembly bolts 18 1.8 13.5
Transmission to engine bolts and nuts 85 8.5 61.5
Engine rear mounting bolts
Engine rear mounting member bolts50 5.0 36.5
Universal joint flange bolts and nuts 50 5.0 36.5
Torque converter mounting bolts 65 6.5 47.0
Adapter case or extension case bolts 42 4.2 30.0
Transmission range switch lock bolt 5.5 0.55 4.0
Oil pipe union bolts 35 3.5 22.5
Drive plate bolts 78 7.8 56.5
Interlock cable clamp screw 2.2 0.22 1.5
Interlock cable outer mounting nut 13 1.3 9.5

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-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-11
4) In the same manner as described in Step 1), install thrust
washer (2), spring washer (1) and differential gear (4).
5) Install differential left case (1) and then tighten screws to
specified torque.
“A” : Cement 99000-32110
Tightening torque
Differential case screw (a) :
9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Clean and degrease mating surface of drive bevel gear
(hypoid gear) (1).
7) Apply thread lock cement to hatched part of drive bevel gear
(1) as shown in the figure.
“A” : Cement 99000-32110
8) Put drive bevel gear (3) on differential case (1) and fasten
them with bolts (2) by tightening them to specified torque.
Use thread lock cement for bolts (2).
“A” : Cement 99000-32110
Tightening torque
Bevel gear bolts (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft)
3. Differential left case
5. Differential pinion
3 Differential right case1
2, (a), “A”
32, (a), “A”
“
A”
1
CAUTION:
Use of any other bolts than that specified is prohibited.1
2, (a), “A”
3

DIFFERENTIAL (REAR) 7F-15
3) Set dial gauge to mounting dummy and make 0 (zero)
adjustment on surface plate.
Special tool
(A) : 09900-20606
(B): 09926-78320
4) Place zero-adjusted mounting dummy and dial gauge set on
pinion mounting dummy and take measurement between
zero position and extended dial gauge measuring tip.
Special tool
(A) : 09900-20606
(B) : 09926-78311
(D) : 09922-76570
(F) : 09926-78311-002
5) Obtain adjusting shim thickness by using measured value by
dial gauge in previous step. NOTE:
When setting dial gauge to mounting dummy, tighten
screw lightly. Be careful not to overtighten it, which will
cause damage to dial gauge.
With dial gauge set, turn dummy back and force by
hand a couple of times and attain accurate 0 (zero)
adjustment.
It is desirable that short pointer indicates beyond 2 mm
when long one is at 0 (zero).
1. Surface plate
2. Screw
NOTE:
Repeat turning back and force of dummy and measure
distance as far as top surface of pinion dummy accu-
rately.
When dial gauge measuring tip extends from 0 (zero)
position, pointer turns counterclockwise.
Measured value may exceed 1 mm. Therefore, it is also
necessary to know reading of short pointer.
Neces-
sary shim
thickness
“e”=Dial gauge
measured
value “c”

DIFFERENTIAL (REAR) 7F-19
7) Measure preload of pinion bearing with spring balance (1) or
torque wrench (2) and check composite preload of pinion
bearing and side bearing.
Composite preload of pinion bearing and side bearing
: 1.1 – 2.0 N·m (11.0 – 20.0 kg-cm, 9.5 – 17.4 lb-in.)
Spring measure reading with special tool
: 19.5 – 35.5 N (1.95 – 3.55 kg, 4.30 – 7.83 lb)
Special tool
(D) : 09922-76560
8) Torque bearing cap bolts (2) to specification and install bear-
ing lock plates.
Tightening torque
Lock plate bolt (b) : 12 N·m (1.2 kg-m, 9.0 lb-ft)
Bearing cap bolt (c) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
9) As final step, check gear tooth contact as follows.
a) After cleaning 10 drive bevel gear teeth, paint them with
gear marking compound evenly by using brush or sponge
etc.
b) Turn gear to bring its painted part in mesh with drive bevel
pinion and turn it back and forth by hand to repeat their con-
tact.
c) Bring painted part up and check contact pattern, referring
to following chart. If contact pattern is not normal, readjust
or replace as necessary according to instruction in chart. NOTE:
Before taking measurement with spring balance (1) or
torque wrench (2), check for smooth rotation by hand.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
3. Universal joint flange
4. Socket with adapter
1. Lock plate bolt
NOTE:
Be careful not to turn drive bevel gear more than one full
revolution, for it will hinder accurate check.
1. Brush
“A”: Paint gear marking compound evenly

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