2001 SUZUKI GRAND VITARA section 6

7B1-44 AUTOMATIC TRANSMISSION (4 A/T)
LEVEL CHECK AT ROOM TEMPERATURE
The fluid level check at room temperature (20 – 30 °C (68 – 86
°F)) performed after repair or fluid change before test driving is
just preparation for level check of normal operating temperature.
The checking procedure itself is the same as that described previ-
ously. If the fluid level is between FULL COLD and LOW COLD,
proceed to test drive. And when the fluid temperature has
reached the normal operating temperature, check fluid level again
and adjust it as necessary.
Fluid change
1) Lift up vehicle.
2) With engine is cool, remove drain plug (1) from oil pan and
drain A/T fluid.
3) Install drain plug (1).
Tightening torque
A/T fluid drain plug (a) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Lower vehicle and fill proper amount of an equivalent of
DEXRON
®-III.
5) Check fluid level referring to “LEVEL CHECK NORMAL
OPERATING TEMPERATURE” of “FLUID LEVEL” in this
section.
Fluid specification :
An equivalent of DEXRON
®-III
Fluid capacity
When draining from drain plug hole:
2.5 liters (5.28/4.40 US/lmp.pt.)
When overhauling:
6.8 liters (14.37/11.97 US/lmp.pt.)

AUTOMATIC TRANSMISSION (4 A/T) 7B1-49
Unit Repair
Sub-Assembly Repair
Overdrive (case side)
DISASSEMBLY
1) Measure clearance between retaining ring (1) and brake
backing plate (2) with thickness gauge.
If it is not within standard range, replace brake disc or brake
plate.
Clearance between retaining ring and brake backing plate
Standard :
0.40 – 0.90 mm (0.016 – 0.035 in.)
2) Remove retaining ring (1), brake backing plate (2), brake
disc (3), brake plate (4), cushion brake plate (5) in that order.
Then remove planetary ring gear, thrust bearing race and
thrust rear bearing.
3) Remove retaining ring (1), retainer (2) and piston return
spring (3). NOTE:
The service procedure to be described in this item is the same as that of H25 engine model except the
following description.
Refer to the same section of the Unit Repair Manual mentioned in FOREWORD of this manual for the
description not found in this item.

7B1-52 AUTOMATIC TRANSMISSION (4 A/T)
5) Remove retaining ring (1) and then remove direct clutch
input hub.
6) Remove retaining ring and then remove all clutch discs.
7) Using special tool and hydraulic press, compress forward
clutch piston return spring and remove retaining return
spring.
Special tool
(A) : 09926-98310
8) Remove forward clutch piston return spring.
9) Install forward clutch to O/D case. Blow low pressure air into
fluid hole at the right of cut in O/D case to remove forward
clutch piston.
CAUTION:
Be careful when applying pressure, for overpressure will
cause plate section of piston return spring to deform.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-53
DIRECT CLUTCH
DISASSEMBLY
1) Install direct clutch assembly (1) to center support (2) and
with 4 – 8 kg/cm
2 air pressure applied to second fluid hole
from the left, measure stroke of direct clutch piston as shown
in figure.
If it is not within standard range, use 3.55 mm, 3.75 mm or
4.0 mm (0.140 in., 0.147 in. or 0.157 in.) clutch backing plate
to adjust it to standard stroke.
Standard direct clutch piston stroke :
0.90 – 1.30 mm (0.035 – 0.051 in.)
2) Remove direct clutch assembly from center support and
then remove retaining ring.
3) Remove clutch backing plate (1) and then remove clutch
disc (3) and clutch plate (2).
4) Using special tool and hydraulic press (1), compress direct
clutch piston return spring (3) and remove retaining return
spring ring (2).
Special tool
(A) : 09926-98310
5) Remove direct clutch piston return spring.
CAUTION:
Be careful when applying pressure, for overpressure will
cause plate section of piston return spring to deform.

CLUTCH 7C1-1
7C1
SECTION 7C1
CLUTCH
NOTE:
The clutch of this model is the same as that of H25 engine in the construction and operation.
Refer to the same section of the Service Manual mentioned in the FOREWORD of this manual for ser-
vice procedure.

DIFFERENTIAL (FRONT) 7E-1
7E
SECTION 7E
DIFFERENTIAL (FRONT)
CONTENTS
General Description ........................................ 7E-2
4WD Control System ..................................... 7E-2
System circuit ............................................ 7E-2
Diagnosis ......................................................... 7E-3
Differential Assembly Diagnosis Table .......... 7E-3
4WD Control System Diagnostic Flow Table 7E-3
Notes on system circuit inspection ............ 7E-3
Flow table .................................................. 7E-4
4WD Control System Circuit Inspection ........ 7E-5
Voltage check ............................................ 7E-54WD Control System Inspection ................... 7E-6
On-Vehicle Service ......................................... 7E-7
Differential Mountings ................................... 7E-7
Rear Mounting for Front Differential Carrier.. 7E-8
Front Differential Assembly ........................... 7E-9
Unit Repair ..................................................... 7E-11
Tightening Torque Specification ................. 7E-11
Special Tool ................................................... 7E-11

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.

DIFFERENTIAL (FRONT) 7E-3
Diagnosis
Differential Assembly Diagnosis Table
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to “4WD CONTROL SYSTEM INSPECTION” in
this section for air leakage.
Notes on system circuit inspection
•Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before circuit
inspection and observe what is written there.
•For system circuit, refer to the figure of “GENERAL DESCRIPTION” in this section.
•For terminal arrangement, refer to “4WD CONTROL CIRCUIT INSPECTION” in this section. Condition Possible Cause Correction
Gear noiseDeteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion and gear Adjust.
Improper tooth contact in the mesh between bevel pinion
and gearAdjust or replace.
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise(Constant noise) Deteriorated or water mixed lubricant Repair and replenish.
(Constant noise) Inadequate or insufficientlubricant Repair and replenish.
(Noise while coasting) Damaged bearing(s) of bevel pinion Replace.
(Noise while turning) Damaged differential side bearing(s)
or axle bearing(s)Replace.
Oil leakageWorn or damaged oil seal Replace.
Excessive oil Adjust oil level.
Loose differential carrier bolts Replace or retighten.
2WD/4WD
switching errorDefective actuator Replace.
Abnormality in 4WD control system Inspect referring to “4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLE”.

7E-4 DIFFERENTIAL (FRONT)
Flow table
Step Action Yes No
1 Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2. A trouble has occurred
at some place. Repair
it referring to
MALFUNCTION INDI-
CATOR LAMP
(“CHECK ENGINE”
LAMP) CHECK in
DIAGNOSIS of Sec-
tion 6.
2 Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-3-7 and terminal C51-3-17
(ground) is as follows.
 When transfer shift lever is in N or 2H : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?Go to step 3. Check 4WD switch
(refer to Section 7A),
“BLK/ORN” and “BLK”
circuits of 4WD switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3 Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-1-9 and C51-3-17
(ground). The check results should be as follows.
 When transfer shift lever is in N or 2H : 0 – 1 V
 When transfer shift lever is in 4L or 4H : 10 – 14 V
Is the check result satisfactory?Go to step 4. Check “RED” circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4 Check air pump assembly circuit.
1) Check for proper connection to air pump assem-
bly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-3-18 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 0 – 1 V
 When transfer shift lever is in 4L or 4H (more than
4 seconds after shifted to 4L or 4H) : 10 – 14 V
Is the check result satisfactory?Go to step 5. Check air pump
assembly referring to
“ON-VEHICLE SER-
VICE”, and then
“PNK” circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5 Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground). The check result should be as follows.
 When transfer shift lever is in 2H or N : 10 – 14 V
 When transfer shift lever is in 4L or 4H : 0 – 1 V
Is the check result satisfactory?4WD control system is
in good condition.Check “ORN/BLK” cir-
cuit (including indica-
tor lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.