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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 vehicleTo 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
99000-31090To 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
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Viscosity chart
SAE
1. Reverse idle gear shaft bolt
(DO NOT LOOSEN IT)
MANUAL TRANSMISSION (TYPE 1) 7A-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:
It is highly recommended to use SAE 75W-90 gear oil.
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.
If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 1.5 liters (3.2 / 2.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to its thread.
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
Do not loosen or remove reverse idle gear shaft bolt.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
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Viscosity chart
SAE
Temperature
1. Drain plug
2. Oil level / filler plug
MANUAL TRANSMISSION (TYPE 2) 7A1-3
ON-VEHICLE SERVICE
GEAR OIL
INSPECTION AND CHANGE
1) Before changing or inspecting oil, be sure to stop engine and lift
vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage ex-
ists, correct or repair it.
3) Drain old oil and fill new specified oil as shown below by speci-
fied amount (roughly up to level hole).
NOTE:
It is highly recommended to use SAE 75W-90 gear oil.
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.
If water or rust is mixed in drained oil, be sure to check
breather hose and boot of transmission and transfer.
Gear Oil Specification
Oil grade: API GL-4
Viscosity: SAE 75W-85, 75W-90 or 80W-90
Oil Capacity:
Transmission 2.6 liters (5.5 / 4.6 US / Imp. pt)
Transfer 1.7 liters (3.6 / 3.0 US / Imp. pt)
4) Torque drain plug and level / filler plug as specified below after
applying sealant to thread of plug (c).
CAUTION:
Transmission oil must not be poured through gear shift
control lever part.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 38 N´m (3.8 kg-m, 27.5 lb-ft)
(b): 23 N´m (2.3 kg-m, 17.0 lb-ft)
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7B1-4 AUTOMATIC TRANSMISSION (4 A / T)
ItemSpecifications
Torque
conver-
terType
Stall torque ratio3-element, 1-step, 2-phase type (with TCC (lock-up)
mechanism)
2.4 (G16 engine) 2.0 (J20 engine) 1.9 (H25 engine)
Oil
pumpType
Drive systemTrochoid type oil pump
Engine driven
TypeForward 4-step, reverse 1-step planetary gear type
Shift position
ªPº range Gear in neutral, output shaft fixed,engine start
ªRº range Reverse
ªNº range Gear in neutral, engine start
ªDº range Forward 1st 2nd 3rd 4th (O / D)
(O / D ON) automatic gear change
ªDº range Forward 1st 2nd 3rd
(O / D OFF) automatic gear change
ª2º range (Normal mode) Forward 1st 2nd 3rd automatic gear
change
(Power mode) Forward 2nd 3rd automatic gear
change and fixed at 2nd gear
ªLº range Forward 1st 2nd 3rd reduction, and fixed at 1st gear
GearEngine typeG16 engineJ20 / H25 engines
change
device1st (low gear)2.8262.826device2nd (second gear)1.4931.493
Gear3rd (top gear)1.0001.000Gear
ratio4th (overdrive
4th gear)0.7300.689
Reverse (reverse
Reverse gear)2.7032.703
Control elements
Wet type multi-disc clutch 3 sets. . . . . . . . . .
Wet type multi-disc brake 4 sets. . . . . . . . . .
One-way clutch 3 sets. . . . . . . . . . . . . . . . . . .
TransferHi: 1.000 Lo: 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125 (G16 engine) 4.875 (J20 / H25 engines)
Lubrica-
tionLubrication systemForce feed system by oil pump
CoolingCooling systemRadiator assisted cooling (water-cooled)
Fluid usedAn equivalent of DEXRONIII
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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.
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DIFFERENTIAL (FRONT) 7E-5
DIAGNOSIS
DIAGNOSIS TABLE
Differential Assembly
ConditionPossible CauseCorrection
Gear noiseDeteriorated 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
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 leakageWorn or damaged oil seal
Excessive oil
Loose differential carrier boltsReplace
Adjust oil level
Replace or retighten
2WD / 4WD
switching errorDefective actuator
Abnormality in 4WD control systemReplace
Inspect referring to ª4WD
CONTROL SYSTEM DIAG-
NOSTIC FLOW TABLEº.
4WD Control System Diagnostic Flow Table
Before performing the trouble diagnosis, check that the transfer and front differential are in good condition and
there is no air leakage from air hoses and the actuator. Refer to ªON-VEHICLE SERVICEº in this section for air
leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]
Be sure to read ªPrecautions for Electrical Circuit Serviceº in Section 0A before circuit inspection and observe
what is written there.
For system circuit, refer to the figure of ªGENERAL DESCRIPTIONº in this section.
For terminal arrangement, refer to ª4WD Control Circuit Inspectionº in this section.
Page 511 of 801
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DIFFERENTIAL (FRONT) 7E-9
Viscosity chart SAE
Temperature
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.
Gear Oil Change
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 be-
low (roughly up to level hole).
4) Apply sealant to thread of drain plug (b) and torque plugs to
specification.
Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W ± 85, 90 or 80W ± 90
For oil viscosity, refer to left chart.
Oil capacity: 1.0 liters (2.1 / 1.8 US / lmp. pt)
Page 521 of 801
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7F-2 DIFFERENTIAL (REAR)
DIAGNOSIS
ConditionPossible CauseCorrection
Gear noiseDeteriorated 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 leakageClogged breather plug
Worn or damaged oil seal
Excessive oilClean
Replace
Adjust oil level
