2003 SUZUKI GRAND VITARA differential mount

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-13
1. Mounting bracket bolt
2. Mounting bracket R
3. Differential housing
4. Mounting front bolt
1. Differential housing
2. Mounting front bolt3. Mounting bracket L
4. Mounting bracket bolt
1. Mounting bracket
1. Mounting bracket L
2. Bush3. Mounting bracket R
A: Slit alignment 45
4
2
3
1
2
REMOVAL AND INSTALLATION
Differential Mountings
1) Lift up vehicle and turn steering wheel all way to the right.
2) Separate mounting bracket R from differential housing by re-
moving bolts from its lower part.
3) Remove mounting bracket R by removing mounting front bolt
from its upper part.
4) Remove mounting bracket L by removing upper and lower fas-
tening bolts.
5) Check conditions of each bush. If it is damaged or deteriorated,
drive it out with special tools and press for replacement.
Special Tool
(A): 09951-26010
(B): 09951-16080
6) Position slit in each bush as shown when press-fitting it.

YH4
GRAND
VITARA
7E-14 DIFFERENTIAL (FRONT)
1. Mounting bracket R
2. Mounting bracket L
1. Bolt and nut
2. Differential carrier
3. Cross member
4. Bolt
5. Differential rear mounting assembly
7) Position each bush to bracket as shown.
Length ªaº: 3.0 mm (0.12 in.)
8) Use following torque for reinstallation.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
REAR MOUNTING
(For front differential carrier)
1) Lift up vehicle and remove mounting assembly by removing 2
bolts and nuts from differential carrier side and 2 bolts from cross
member side.
2) Check mounting rubber for damage or deterioration and replace
as necessary.
3) Use following torque for reinstallation.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-15
A: Match marks
1. Mounting bracket bolt
2. Flange bolt and nut
1. Bolts
1. Mounting bracket bolt
2. Mounting bracket R
3. Differential housing
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 on joint
flange and propeller shaft as shown.
4) Remove propeller shaft flange by removing its 4 bolts and sus-
pend it with cord or the like.
NOTE:
If pull out propeller shaft, transfer oil must be drained be-
fore pulling out.
5) Remove 3 bolts for left mounting bracket and 3 bolts for drive
shaft flange to set left side of differential free.
6) Remove 2 bolts from cross member to set differential rear
mounting free.
7) With differential housing assembly held with transmission jack,
remove mounting bolts on right end of housing.

YH4
GRAND
VITARA
7E-16 DIFFERENTIAL (FRONT)
(a)
(a)
(a)
1. Drive shaft joint R
2. Differential housing3. Transmission jack
4. Screw driver
8) Using 2 large screwdrivers as levers, pull out right side drive
shaft joint from differential and dismount housing assembly from
vehicle.
CAUTION:
During above work, use care not to cause damage to
drive shaft boot.
REMOUNTING
For remounting, reverse dismounting procedure and use following
tightening torque.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
After tightening all fasteners properly, fill hypoid gear oil as speci-
fied and check tightening of plugs with specification.

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-17
09951-16080
Bearing installer09951-26010
Bush remover plate09918-18110
Air pressure regulator
09367-04002
3-way joint
UNIT REPAIR
Refer to the same section of UNIT REPAIR MANUAL mentioned in FOREWORD of this manual.
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mKg-mlb-ft
Differential oil filler / level plug232.317.0
Differential oil drain plug232.317.0
Differential mounting front bolts858.561.5
Differential mounting bracket bolts505.036.5
Front drive shaft flange bolts505.036.5
Propeller shaft flange bolts505.036.5
Pump assembly bolts131.39.5
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
SealantSUZUKI BOND NO. 1215
(99000-31110)Front differential drain plug
SPECIAL TOOLS

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
1. Breather hose
2. Oil filler / level plug
3. Rear drain plug
(Apply sealant)
Viscosity chart SAE
DIFFERENTIAL (REAR) 7F-3
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter has entered (if so, oil is cloudy). Water mixed oil must be
changed at once.

Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status
of breather hoses.
CHANGING OIL
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W-90 viscosity.
1) Before oil change or inspection, be sure to stop engine and lift
up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain and level / filler plugs to specification.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(b): 28 N
.m (2.8 kg-m, 20.5 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W-85, 80W-90 or 90
For oil viscosity, refer to the chart
at the left.
Oil capacity : 2.2 liters (4.6 / 3.9 US / Imp. pt.)

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.