2004 SUZUKI GRAND VITARA maintenance

YH4
GRAND
VITARA
1. Dipstick (G16 / J20)
2. Dipstick (H25)
AUTOMATIC TRANSMISSION (4 A / T) 7B1-59
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
FLUID LEVEL
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal operating
temperature (70 ± 80C / 158 ± 176F). As a guide to check fluid
temperature, warm up engine till engine coolant temperature
meter indicated around 1 unit above ªCº point.
5) Keep engine idling and shift selector slowly to L and back to P
position.
6) With engine idling, pull out dipstick, wipe it off with a clean cloth
and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it. Fluid
level should be between FULL HOT and LOW HOT. If it is below
LOW HOT, add an equivalent of DEXRON-III up to FULL HOT.
Fluid specification
An equivalent of DEXRON-III
NOTE:

DO NOT RACE ENGINE while checking fluid level, even af-
ter the engine start.

DO NOT OVERFILL. Overfilling can causes foaming and
loss of fluid through breather. Then slippage and trans-
mission failure can result.

Bringing the level from LOW HOT to FULL HOT requires
0.3 liters (0.64/0.53 US/lmp.pt).

If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour af-
ter it is stopped.

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

YH4
GRAND
VITARA
7E
DIFFERENTIAL (FRONT) 7E-1
The differential assembly using a hypoid bevel pinion
and gear is installed to the front axle.
4WD control system controls drive force to be trans-
mitted to front axles or not. The reduction ratio varies
depending on transmission or engine type.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 7E
DIFFERENTIAL (FRONT)
CONTENTS
GENERAL DESCRIPTION7E- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD CONTROL SYSTEM7E- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS TABLE7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly7E- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Control System Diagnostic Flow Table 7E- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD CONTROL CIRCUIT INSPECTION 7E- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Oil Change7E- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION7E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WD Control System7E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator7E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Pump Assembly7E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION 7E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Mountings7E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISMOUNTING7E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOUNTING7E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS7E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION

YH4
GRAND
VITARA
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)

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.)