2001 SUZUKI GRAND VITARA Owners Manual

7F-12 DIFFERENTIAL (REAR)
9) Install special tool to differential case assembly and check
that preload is within specification below. If preload exceeds
specified value, check if foreign matter is caught or gear is
damaged.
Special tool
(B) : 09928-06510
Side gear preload
: Max. 2.5 N·m (0.25 kg-m, 1.8 lb-ft)
Differential side bearing
1) Press-fit side bearing (1) with special tool and press.
Special tool
(A) : 09944-66020
2) Hold bearing press-fitted in Step 1) with holder and press-fit
side bearing on the other side.
Special tool
(A) : 09944-66020
(B) : 09951-16060
1. Torque wrench
2. Differential case assembly
3. Aluminum plate
4. Vise
(A)
1
NOTE:
Be sure to use bearing holder for the purpose of protect-
ing lower bearing.

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-14 DIFFERENTIAL (REAR)
1) Install special tools with bearings and universal joint flange
(2) to differential carrier (1).
Special tool
(E) : 09951-46010
(F) : 09926-78311-002
2) Tighten flange nut (1) so that specified bearing preload is
obtained.
Special tool
(C) : 09922-75222
(F) : 09926-78311-002
Pinion bearing preload
: 0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)
Spring measure reading with special tool
: 18N – 34N (1.8 – 3.4 kg, 4.0 – 7.5 lb) NOTE:
This installation requires no spacer or oil seal.
NOTE:
Before taking measurement with spring balance (2) or
torque wrench (3), check for rotation by hand and apply
small amount of differential oil to bearings.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
4. Socket with adapter

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”

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

DIFFERENTIAL (REAR) 7F-17
9) While tightening flange nut gradually with special tool and
power wrench (4 - 10 magnification) (1), set preload of pinion
to specification.
Pinion bearing preload
: 0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)
Spring measure reading with special tool
: 16 – 30 N (1.6 – 3.0 kg, 3.5 – 6.6 lb)
Special tool
(C) : 09922-76560
(J) : 09922-66021 NOTE:
Before taking measurement with spring balance (3) or
torque wrench (4), check for smooth rotation by hand.
On measuring preload, rotate the drive bevel pinion
about 1 rotation per 2 seconds.
Be sure to tighten gradually and carefully till specified
starting torque is obtained. Turning back overtightened
flange nuts should be avoided.
2. Socket wrench

7F-18 DIFFERENTIAL (REAR)
Assembling Unit
1) Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2) Install case assembly in carrier.
3) Install side bearing adjusters on their respective carrier,
making sure adjuster are threaded properly.
4) Align match marks (1) on cap and carrier. Screw in 2 side
bearing cap bolts 2 or 3 turns and press down bearing cap
by hand.
5) Tighten cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque) (a) :
15 N·m (1.5 kg-m, 11.0 lb-ft)
6) Tighten both bearing adjusters (2) so as to obtain specified
gear backlash and at the same time, obtain preload of side
bearing.
Standard backlash
: 0.13 – 0.18 mm (0.005 – 0.007 in.)
Special tool
(A) : 09930-40120
(B) : 09930-40113
(C) : 09900-20701
NOTE:
If bearing cap does not fit tightly on carrier, side bearing
adjuster is not threaded properly. Reinstall adjuster.
NOTE:
Be sure to apply measuring tip of dial gauge at right
angles to convex side of tooth.
As a practical measure the following would be recom-
mended to obtain specified backlash and side bearing
preload at the same time.
–Obtain specified backlash by turning both adjusters
inward lightly.
–Tighten both adjusters further by one notch at a
time.
Measure at least 4 points on drive bevel gear periph-
ery.
1. Bearing cap bolt

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