2004 SUZUKI GRAND VITARA sec 8

YH4
GRAND
VITARA
1. Pipe
2. Hose
3. Flare nut
1. Pipe
2. Hose
3. Flare nut
4. E-ring
1. Master cylinder
assembly
2. Clutch pipe
3. Attaching nut
4. Attaching bolt
5. Clevis pin
6. Clip
7. Flare nut
CLUTCH 7C1-5
INSPECTION
Check pipe and hose for dent, kink, crack, dirt and dust. Replace
if check result is not satisfactory.
INSTALLATION
Reverse removal sequence noting following points.
Tighten flare nuts to specified torque.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
NOTE:

For air bleeding of master cylinder alone, it must be removed
from vehicle.
(For procedures of removal and installation of master cylin-
der assembly and air bleeding, refer to CLUTCH MASTER
CYLINDER section.)

Do not allow fluid to get on painted surface.

Do not allow pipe and hose to contact hard against vehicle
or other parts.

Install each clamp securely.

Install E-ring securely as shown.

After installation, check clutch pedal free travel and bleed air
from system.

Check fluid leakage.

Add fluid close to MAX level of reservoir.
CLUTCH MASTER CYLINDER
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Remove push rod clevis pin.
3) Disconnect fluid pipe from master cylinder.
NOTE:
Do not allow fluid to get on painted surfaces.
4) Remove master cylinder attaching nut and bolt.
5) Remove master cylinder assembly and gasket.

YH4
GRAND
VITARA
1. Master cylinder
1. Attaching bolt
2. Attaching nut
3. Clevis pin
ªAº
7C1-6 CLUTCH
INSTALLATION
1) To bleed air from master cylinder itself, tilt it as shown in figure
and add fluid into it.
NOTE:
After bleeding air from master cylinder, plug pipe hole in it
to prevent fluid from spilling out of it till pipe is connected.
2) Install master cylinder assembly and new gasket to body, attach-
ing bolt, nuts and push rod clevis pin.
NOTE:
Do not reuse gasket.
3) Torque attaching bolt and nut to specification.
4) Connect fluid pipe and torque flare nut to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
5) Apply grease to clevis pin and install it.
ªAº: Grease 99000-25010
6) Fill reservoir with specified brake fluid and check fluid leakage.
7) After installation, bleed air from system and check clutch pedal
free travel. Refer to BRAKE section for air bleeding procedure.
FLUID INSPECTION
Fluid level should be always between MIN and MAX lines on reser-
voir. If fluid decreases quickly, check for leakage, repair leaky point,
if any, and add fluid up to MAX level.
NOTE:

Brake fluid damages painted surface badly. Should it get on
painted surface, remove it immediately and clean surface
thoroughly.

Do not use shock absorber fluid or any other fluid which con-
tains mineral oil. Do not use container which has been used
for mineral oil or which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic
clutch system and water will mix with brake fluid, lowering
fluid boiling point. Keep all fluid containers capped to pre-
vent contamination.

Make sure not to use fluid whose container cap was first
opened more than a year ago.

YH4
GRAND
VITARA
ªAº
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Clutch operating cylinder
2. Hose
3. E-ring
7C1-8 CLUTCH
4) Tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
5) For installation of master cylinder to vehicle, refer to INSTALLA-
TION described previously.
CLUTCH OPERATING CYLINDER
REMOVAL
NOTE:
Do not allow fluid to get on painted surfaces.
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Disconnect fluid hose from operating cylinder.
3) Remove operating cylinder attaching bolts and operating cylin-
der.
INSTALLATION
1) For air bleeding of master cylinder alone, it must be removed
from vehicle.
For procedures of removal and installation of master cylinder as-
sembly and air bleeding, refer to CLUTCH MASTER CYLINDER
section.
2) Apply small amount of grease to rod tip.
ªAº: Grease 99000-25010
NOTE:
Don't allow any grease to be on boot.
3) Install clutch operating cylinder and torque attaching bolts to
specification.
4) Connect clutch fluid hose and torque union bolt to specification.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)

YH4
GRAND
VITARA
CLUTCH 7C1-9
5) Fill reservoir with specified brake fluid and check for fluid leak-
age.
6) Bleed air from system and check clutch pedal free travel. Refer
to BRAKE section for air bleeding procedure.

YH4
GRAND
VITARA
7C1-10 CLUTCH
(B)1
12
(A)
1. Input shaft bearing
2. Flywheel
3. Clutch disc
4. Clutch cover
5. Bolt
6. Release bearing
7. Clutch release fork
8. Boot
9. Clip
10. Clutch release fork support
1. Bolt
2. Clutch cover
1. Input shaft bearing
UNIT REPAIR
CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
DISMOUNTING / REMOUNTING
Refer to SECTION 7A ªDismounting / Remounting of Trans Unitº.
REMOVAL
1) Hold flywheel stationary with special tool (A) and remove clutch
cover bolts, clutch cover and clutch disc.
Special Tool
(A): 09924-17810
2) Pull out input shaft bearing by using special tool (B) and wrench.
Special Tool
(B): 09917-58010 (G16 engine)
(B): 09923-73210 (J20 and H25 engines)
3) Remove release bearing and release fork.

YH4
GRAND
VITARA
CLUTCH 7C1-13
1. Release fork
2. Clip
3. Input shaftªBº
ªBº
ªAº 3
2
1
1
2
4) Install clip to release fork and apply grease.
ªAº: Grease 99000-25010
Then install release fork and release bearing as shown in figure.
5) Slightly apply grease to input shaft and install clutch disc. Then
join transmission transfer assembly with engine. Refer to SEC-
TION 7A.
ªBº: Grease 99000-25210
NOTE:
Turn crankshaft with wrench from front while inserting
transmission input shaft to clutch disc until splines mesh.

YH4
GRAND
VITARA
7D
TRANSFER 7D-1
The aluminum transfer case directly connected to the
back of the transmission contains the input gear,
countershaft & gear, output rear shaft, output low gear
and output front shaft (for front drive) connected by
way of the hyvo-chain.
The transfer has such a selective mechanism as to
enable the shift control lever to make selection of high
speed (direct connection with transmission output:
main shaft), low speed (speed reduction by input
gear, counter gear and output low gear) or neutral by
way of the reduction sleeve located between input
gear and output low gear, and selection of two-wheel-
drive (high speed only) or four-wheel-drive (high or
low speed) by way of the front drive clutch sleeve lo-cated at the center of the output rear shaft. Also, with
a synchronizer installed to the front drive clutch, it is
possible to change the drive mode between 2WD
(high speed only) and 4WD (high speed only) even
while running.
The front drive shift fork has an auxiliary spring to
make a smooth shift from 4H to 2H possible.
The case has an oil gutter and a plate at synchronizer
to provide proper lubrication even under the strict
conditions of use.
WARNING:
For towing the vehicle for the purpose of repair or
the like, follow the towing instructions in OWN-
ER'S MANUAL.
SECTION 7D
TRANSFER
CONTENTS
GENERAL DESCRIPTION7D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table7D-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Oil Seals7D-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Driven Gear7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting7D-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Assembly7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting7D-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remounting7D-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL7D-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
7D-2 TRANSFER
DIAGNOSIS
DIAGNOSIS TABLE
Before attempting to repair the transfer or related components for any reason other than mechanical failure, the
condition and probable causes should be identified.
Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding.
When any of these conditions occur, the following inspections should be made before disassembling the transfer.
1) Check transfer oil level for insufficient or incorrect oil. Refer to ªTransfer and Differential Oil Inspection and
Changeº in SECTION 0B ªMAINTENANCE AND LUBRICATIONº.
2) Check transfer mountings for wear or looseness.
3) Check gearshift control lever for distortion or excessive wear.
After performing the above inspections, refer to following diagnosis table.
Condition
Possible CauseCorrection
Gear slipping out of mesh
Worn shift fork shaft

Worn shift fork or synchronizer sleeve

Weak or damaged locating spring

Worn bearings on output rear shaft

Worn chamfered tooth on sleeve or gear

Missing or disengagement of circlip(s)Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Gears refusing to disengage
Weakened or broken synchronizer spring

Distorted shift shaft or shift forkReplace
Replace
Hard shifting
Weakened front drive shift shaft spring

Distorted or mispositioned front drive shift
shaft circlip and washer

Inadequate or insufficient lubricant

Worn synchronizer ring

Worn chamfered tooth on sleeve or gear

Distorted shift shaftReplace
Replace
Replenish
Replace
Replace sleeve and gear
Replace
Noise
Inadequate or insufficient lubricant

Damaged or worn bearing(s)

Damaged or worn gear(s)

Damaged or worn synchronizer ring

Damaged or worn chamfered tooth on
sleeve or gearReplenish
Replace
Replace
Replace
Replace