2002 SUZUKI GRAND VITARA Assembly

YH4
GRAND
VITARA
1. Paint
3F-4 WHEELS AND TIRES
Higher than Recommended Pressure Can Cause:
1. Hard ride
2. Tire bruising or carcass damage
3. Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1. Uneven braking
2. Steering lead
3. Reduced handling
4. Swerve on acceleration
Valve caps should be kept on valves to keep dust and
water out.Lower than Recommended Pressure Can Cause:
1. Tire squeal on turns
2. Hard steering
3. Rapid and uneven wear on the edges of the tread
4. Tire rim bruises and rupture
5. Tire cord breakage
6. High tire temperatures
7. Reduced handling
8. High fuel consumption
MAINTENANCE AND MINOR ADJUSTMENTS
WHEEL AND TIRE
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
STUDS
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
MATCHED TIRES AND WHEELS
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or ªhigh spotº, is
matched to the smallest radius or ªlow spotº of the wheel.
This is done to provide the smoothest possible ride.
The ªhigh spotº of the tire is originally marked by paint dot on the
outboard sidewall. This paint dot will eventually wash off the tire.
The ªlow spotº of the wheel is originally marked by paint dot on the
wheel rim-flange. Properly assembled, the wheel rims' paint dot
should be aligned with the tires' paint dot as shown in left figure.
Whenever a tire is dismounted from its wheel, it should be re-
mounted so that the tire and wheel are matched. If the tire's paint
dot cannot be located, a line should be scribed on the tire and wheel
before dismounting to assure that it is remounted in the same posi-
tion.
INFLATION OF TIRES
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread
wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the side
of instrument panel.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pressure
after driving. Bleeding reduces the ªCold Inflation Pressureº.

YH4
GRAND
VITARA
4A2
1. Drive shaft oil seal
2. Double off set joint (DOJ)
3. Joint circlip
4. DOJ boot
5. Ball joint boot
6. Ball joint assembly (RH side)
7. Drive shaft assembly (LH side)
8. Left drive shaft
9. Drive shaft bearing circlip
10. Drive shaft bearing
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-1
SECTION 4A2
FRONT DRIVE SHAFT/SHAFT BEARING,
OIL SEAL
CONTENTS
GENERAL DESCRIPTION4A2- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS4A2- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table4A2- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Boot And Joint Check 4A2- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE4A2- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft4A2- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Bearing / Oil Seal4A2- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The drive shaft joint is a constant velocity joint (C.V. joint) which slides in the axial direction. The joint is composed
of an outer race, cage, inner race and balls. In the turning direction, the joint rotates in the same way as a ball bear-
ing. The balls lock rotation completely and transmit drive. In addition this vehicle is also characterized by a function
that the shaft can slide through the balls in the grooves of the outer race in the extension / contraction direction of
the drive shaft.

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Drive shaft flange
bolts and nuts
1. Oil seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3
ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange.
3) Remove drive shaft circlip and front spindle thrust washer.
4) Remove drive shaft flange bolts and nuts.
5) Remove drive shaft assembly to differential side as shown in left
figure.
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.
6) Remove drive shaft thrust washer (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
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
1. Boot
2. Snap ring
1. Circlip
2 Snap ring plier
3. Cage
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5
DISASSEMBLY
1) Remove boot band of differential side joint.
2) Slide boot toward the center of shaft and remove snap ring from
outer race, then take shaft out of outer race.
3) Remove circlip and then cage.
4) Remove inside and outside boots from shaft.
CAUTION:

Do not disassemble wheel side joint (outboard joint). If
any malcondition is found in joint, replace it as assem-
bly.

Do not disassemble ball joint of differential side joint.
If any malcondition is found in ball joint, replace differ-
ential side joint assembly.
INSPECTION

Check boots for breakage or deterioration. Replace them as nec-
essary.

Check circlip, snap ring and boot bands for breakage or deforma-
tion. Replace as necessary.
CLEANING

Wash disassembled parts (except boots) in degreaser. After
washing, dry parts completely by blowing air.

Clean boots with cloth. DO NOT wash boots in degreaser, such
as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.

YH4
GRAND
VITARA
1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:

To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.

For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.

Bend each boot band against forward rotation.

Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.

YH4
GRAND
VITARA
1. Drive shaft oil seal
1. Drive shaft flange bolt and nut
2. Front spindle thrust washer
3. Axle shaft drive flange
ªAº
1. Drive shaft joint
2. Oil seal
3. Pipe
4. Thrust washer4
4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.

Clean front drive shaft oil seal and then apply lithium grease to oil
seal and DOJ shaft.
ªAº: Grease 99000-25010

Check oil seal for breakage or deterioration.
Replace it as necessary.

Drive in oil seal until its end contacts stepped surface of drive
shaft joint by using a pipe whose inner diameter is 76 mm (2.992
in.) or more and outer diameter is 80 mm (3.150 in.) or less.
Diameter ªaº: 76 mm (2.992 in.) or more
Diameter ªbº: 80 mm (3.150 in.) or less

Drive in drive shaft thrust washer (Vehicle with G16 or J20 en-
gine).

RH Side
Push differential side joint by hand until it is positioned by snap
ring fitted to its spline.
LH Side
Connect drive shaft flange bolts and nuts.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

Apply grease to front spindle thrust washer and front spindle part
of drive shaft.
ªAº: Grease 99000-25010

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªBº: Sealant 99000-31090
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CAUTION:

To prevent breakage of boots (wheel side and differen-
tial side), be careful not to bring them into contact with
other parts when installing drive shaft assembly.

Do not pull housing of differential side joint.
If housing is pulled, it may be detached from drive shaft.

Fill specified differential gear oil into differential case to specified
level.

YH4
GRAND
VITARA
1. Left drive shaft
2. Tire lever
1. Shaft bearing1. Axle oil seal
2. Circlip
3. Axle bearing
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-9
SHAFT BEARING / OIL SEAL
REMOVAL
1) Remove drive shaft assembly.
Refer to item DRIVE SHAFT REMOVAL (LEFT and RIGHT) in
this section.
For right side shaft bearing / oil seal removal, drain differential
gear oil.
2) Remove left drive shaft by using tire lever.
3) Remove left side strut. Refer to steps 1) and 4) to 8) of item
STRUT DAMPER REMOVAL in Section 3D.
4) Remove oil seal, using plain screw driver.
5) Remove circlip.
6) Remove bearing, using special tools (A) and (B).
Special Tool
(A): 09941-64510
(B): 09930-30102