2001 SUZUKI GRAND VITARA Front diff

DIFFERENTIAL (FRONT) 7E-9
Front Differential Assembly
DISMOUNTING
1) Lift up vehicle and drain oil.
2) Disconnect air hose and breather hose from differential
housing.
3) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown in the figure.
4) Remove propeller shaft flange by removing its 4 bolts and
suspend it with cord or the like.
5) Remove bolts (1) for left mounting bracket and bolts and
nuts (2) for drive shaft flange to set left side of differential
free.
6) Remove bolts (1, 2) and rear mounting bracket (3).
7) Remove bolts (4) and rear mounting bracket No.2 (5).
8) With differential housing assembly held with transmission
jack, remove front mounting bracket (2) bolts (1) on right end
of housing (3). NOTE:
If pull out propeller shaft, transfer oil must be drained
before pulling out.
4 1
2
5
3

7E-10 DIFFERENTIAL (FRONT)
9) Using 2 large screwdrivers (4) as levers, pull out right side
drive shaft joint (1) from differential (2) and dismount housing
assembly from vehicle.
REMOUNTING
For remounting, reverse dismounting procedure and use the fol-
lowing tightening torque.
Tightening torque
Front drive shaft flange bolts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Propeller shaft flange bolts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Front mounting bracket bolts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Rear mounting bracket bolts(a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Rear mounting bolt (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
Rear mounting bracket No.2 bolts (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
After tightening all fasteners properly, fill hypoid gear oil as speci-
fied and check tightening of plugs with specification.CAUTION:
During above work, use care not to cause damage to
drive shaft boot.
(b) (b)
(a)

DIFFERENTIAL (FRONT) 7E-11
Unit Repair
Refer to the same section of “UNIT REPAIR MANUAL” mentioned in “FOREWORD” of this manual.
Tightening Torque Specification
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Front mounting bolts 85 8.5 61.5
Front mounting bracket bolts 50 5.0 36.5
Front drive shaft flange bolts 50 5.0 36.5
Propeller shaft flange bolts 50 5.0 36.5
Rear mounting bolt 85 8.5 61.5
Rear mounting bracket bolts 50 5.0 36.5
Rear mounting bracket No.2 bolts 85 8.5 61.5
09918-18110 09951-16080 09951-26010
Air pressure regulator Bearing installer Bush remover plate

7E-12 DIFFERENTIAL (FRONT)

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

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.

DIFFERENTIAL (REAR) 7F-13
Drive bevel pinion
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier
properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel
pinion, differential carrier and mounting dummy.
Special tool
(A) : 09900-20606
(B) : 09926-78320
(C) : 09922-75222
(D) : 09922-76570
(E) : 09951-46010
(F) : 09926-78311-002
1. Universal Joint flange (P/No. 27110-60A00)“a”: Pinion dummy height + Attachment height
2. Nut“b”: Axle dummy radius
3. Front bearing“a” + “b”Mounting dummy size 110.00 mm/4.3307 in.
4. Differential carrier“c”: Measured dimension
5. Rear bearing“d”: Drive bevel pinion mounting distance 110.00 mm/4.3307 in.
6. Spacer“e”: Shim size for mounting distance adjustment (= “c”)
7. Drive bevel pinion
8. Drive bevel gear

7F-16 DIFFERENTIAL (REAR)
6) Select adjusting shim(s) (2) closest to calculated value from
among following available sizes and put it in place and then
press-fit rear bearing (1).
Calculated valve
“f” : Closest value to “e” (refer to Step 5).)
Special tool
(G) : 09925-18011
(H) : 09927-66010
Available shim thickness
: 1.12, 1.15, 1.18, 1.21,1.24, 1.27, 1.30 and 0.3 mm
(0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)
7) With new pinion spacer (3) inserted as shown in the figure,
install front bearing (5) to differential carrier (4).
8) Using special tool and plastic hammer, drive oil seal (2) into
differential carrier (1) till it becomes flush with carrier end.
Then apply grease “A” to oil seal lip.
“A” : Grease 99000-25010
Special tool
(I) : 09951-18210
3. Drive bevel pinion
NOTE:
Make sure to use new spacer for reinstallation.
Apply differential oil to bearings.
1. Drive bevel pinion
2. Rear bearing