2002 SUZUKI GRAND VITARA rear axle

YH4
GRAND
VITARA
5C-14 PARKING AND REAR BRAKE
1
2
3
1. Brake back plate
2. Cable cap
3. Brake cable
1. Wheel bearing retainer nut
1. Rear axle shaft
2. Wheel bearing
3. Brake back plate(A)
BRAKE BACK PLATE
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Perform steps 3) and 4) of WHEEL CYLINDER REMOVAL.
4) Remove cable from brake back plate by squeezing parking
brake cable cap.
5) Drain rear differential gear oil.
6) Remove wheel bearing retainer nuts from rear axle housing.
7) Using special tools, draw out rear axle shaft with brake back
plate.
Special Tool
(A): 09943-35512
(B): 09942-15510
8) Remove brake back plate from rear axle shaft.

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-15
1. Rear axle shaft
2. Wheel bearing
3. Brake back plate1. Rear axle shaft
1. Rear axle
housing ªAº
INSTALLATION
1) Apply sealant to mating surface of bearing retainer with brake
back plate.
ªAº: Sealant 99000-31110
NOTE:
Make sure to remove old sealant before applying it anew.
2) Install brake back plate to rear axle shaft.
3) Apply sealant to joint seam of rear axle housing and brake back
plate.
ªAº: Sealant 99000-31110
NOTE:
Make sure to remove old sealant before applying it anew.
4) Install rear axle shaft to rear axle housing.
5) Tighten brake back plate nuts to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-17
09943-35512
Brake drum remover
(Front wheel hub remover)09942-15510
Sliding hammer
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Wheel cylinder bleeder plug7.50.755.5
Parking brake lever bolt232.317.0
Wheel cylinder bolt (For non sealed type)8.50.856.5
Wheel cylinder bolt (For gasket sealed type)111.112.0
Brake pipe flare nut161.612.0
Brake back plate nut232.317.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.
Water tight
sealantSEALING COMPOUND 366E
99000-31090
To apply to mating surfaces of brake back
plate and rear wheel cylinder.
SealantSUZUKI BOND NO. 1215
99000-31110

To apply to mating surfaces of brake back
plate and rear axle housing.

To apply mating surfaces of brake back
plate and rear wheel bearing retainer.
SPECIAL TOOLS

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-37
1. Rear wheel speed sensor
2. Sensor rotor
3. Rear axle housing
1. Rear wheel speed
sensor harness
2. Connector
1. Sensor bolt
2. Clamps
REAR WHEEL SPEED SENSOR
OUTPUT VOLTAGE INSPECTION
Check in the same procedure as that used of front wheel speed
sensor check.
Output AC voltage at 2 / 3 to
one rotation per second (25 ± 38 Hz): 106 mV or more
Reference
When using oscilloscope,
peak-to-peak voltage at 2 / 3 to
one rotation per second (25 ± 38 Hz): 150 mV or more
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Disconnect rear wheel speed sensor connector and detach wire
harness from vehicle body and rear axle.
4) Remove harness clamps and remove rear wheel speed sensor
from rear axle.
CAUTION:

Do not pull wire harness when removing rear wheel
speed sensor.

Do not cause damage to surface of rear wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-39
1. Rear axle
2. Retainer ring
3. Sensor rotor
4. Vinyl envelope
ªAº Grind with grinderªAº
1. Sensor rotor 4
31
2
2 1
3
REAR SENSOR ROTOR
REMOVAL
1) Remove rear axle shaft. Refer to REAR AXLE SHAFT RE-
MOVAL in Section 3E.
2) In order to remove sensor rotor from retainer ring, grind with a
grinder one part of the sensor rotor as illustrated till it becomes
thin.
CAUTION:

Cover vinyl sheet or the like over wheel bearing so that
fine grains from grinding will not enter there.

Be careful not to go so far as to grind the retainer ring.
3) Break with a chisel the thin ground sensor rotor, and it can be re-
moved.
INSTALLATION
1) Press-fit sensor rotor as shown.
NOTE:
Use care not to cause any damage to outside of retainer
ring.
2) Install rear axle shaft. Refer to REAR AXLE SHAFT INSTALLA-
TION in Section 3E.

YH4
GRAND
VITARA
7F
DIFFERENTIAL (REAR) 7F-1
The differential assembly is decisive in that the drive
power is concentrated there. Therefore, use of genu-
ine parts and specified torque is compulsory. Further,
because of sliding tooth meshing with high pressure
between bevel pinion and gear, it is mandatory to lu-
bricate them by hypoid gear oil.
SECTION 7F
DIFFERENTIAL (REAR)
CONTENTS
GENERAL DESCRIPTION7F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7F-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Service7F-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7F-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7F-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7F-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7F-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The differential assembly using a hypoid bevel pinion
and gear is installed to the rear axle. It is set in the con-
ventional type axle housing.
The reduction ratio and differential case vary depend-
ing on transmission or engine type.

YH4
GRAND
VITARA
7F-2 DIFFERENTIAL (REAR)
DIAGNOSIS
ConditionPossible CauseCorrection
Gear noise
Deteriorated or water mixed lubricant

Inadequate or insufficient lubricant

Maladjusted backlash between bevel
pinion and gear

Improper tooth contact in the mesh between
bevel pinion and gear

Loose bevel gear securing bolts

Damaged side gear(s) or side pinion(s)Repair and replenish
Repair and replenish
Adjust as prescribed
Adjust or replace
Replace or retighten
Replace
Bearing noise
(Constant noise) Deteriorated or water
mixed lubricant

(Constant noise) Inadequate or insufficient
lubricant

(Noise while coasting) Damaged bearing(s)
of bevel pinion

(Noise while turning) Damaged diff. side
bearing(s) or axle bearing(s)Repair and replenish
Repair and replenish
Replace
Replace
Oil leakage
Clogged breather plug

Worn or damaged oil seal

Excessive oilClean
Replace
Adjust oil level

YH4
GRAND
VITARA
1. Match mark
1. Differential to rear axle nut
7F-4 DIFFERENTIAL (REAR)
DISMOUNTING
1) Lift up vehicle and drain oil from rear differential housing.
2) Remove rear brake drums and pull out right and left rear axle
shafts. (Refer to rear axle shaft removal of SECTION 3E.)
3) Before removing propeller shaft, give match marks on joint
flange and propeller shaft as shown.
4) Remove propeller shaft by removing its 4 flange bolts and nuts.
5) Remove differential assembly by removing its 8 fastening nuts.