2005 SUZUKI GRAND VITARA Service Workshop Manual

YH4
GRAND
VITARA
1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:

To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.

For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.

Bend each boot band against forward rotation.

Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.

YH4
GRAND
VITARA
ªAº: Fill grease 90 ± 95 g (3.2 ± 3.4 oz)
1. Circlip
[LH] [RH] Differential side
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7
7) Apply grease to entire surface of cage.
Use joint grease in tube included in spare part or joint grease
(99000-25120).
8) Insert cage into outer race and fit circlip into groove of outer
race.
CAUTION:
Position opening of circlip ªaº so that it will not be lined
up with a ball.
9) Apply grease to inside of outer race, and fit boot to outer race.
Fill up inside of boot with joint grease.
ªAº: Joint Grease 99000-25120
(about 90 ± 95g / 3.2 ± 3.4 oz)
10) Fitting boot to outer race, adjust so that measurements ªbº and
ªcº become as indicated in figure.
Length ªbº: 203.2 ± 213.2 mm
(8.00 ± 8.40 in.)
196.8 ± 206.8 mm
(7.75 ± 8.14 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
ªcº: 125.5 ± 135.5 mm
(4.94 ± 5.33 in.)
127.5 ± 137.5 mm
(5.02 ± 5.41 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
Before fixing boot band, insert screwdriver into boot on joint
side and allow air to enter boot so that air pressure in boot be-
comes the same as atmospheric pressure.
11) Clamp boot band. Check boots for distortion or dent.

YH4
GRAND
VITARA
1. Drive shaft oil seal
1. Drive shaft flange bolt and nut
2. Front spindle thrust washer
3. Axle shaft drive flange
ªAº
1. Drive shaft joint
2. Oil seal
3. Pipe
4. Thrust washer4
4A2-8 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.

Clean front drive shaft oil seal and then apply lithium grease to oil
seal and DOJ shaft.
ªAº: Grease 99000-25010

Check oil seal for breakage or deterioration.
Replace it as necessary.

Drive in oil seal until its end contacts stepped surface of drive
shaft joint by using a pipe whose inner diameter is 76 mm (2.992
in.) or more and outer diameter is 80 mm (3.150 in.) or less.
Diameter ªaº: 76 mm (2.992 in.) or more
Diameter ªbº: 80 mm (3.150 in.) or less

Drive in drive shaft thrust washer (Vehicle with G16 or J20 en-
gine).

RH Side
Push differential side joint by hand until it is positioned by snap
ring fitted to its spline.
LH Side
Connect drive shaft flange bolts and nuts.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

Apply grease to front spindle thrust washer and front spindle part
of drive shaft.
ªAº: Grease 99000-25010

When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªBº: Sealant 99000-31090
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
CAUTION:

To prevent breakage of boots (wheel side and differen-
tial side), be careful not to bring them into contact with
other parts when installing drive shaft assembly.

Do not pull housing of differential side joint.
If housing is pulled, it may be detached from drive shaft.

Fill specified differential gear oil into differential case to specified
level.

YH4
GRAND
VITARA
1. Left drive shaft
2. Tire lever
1. Shaft bearing1. Axle oil seal
2. Circlip
3. Axle bearing
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-9
SHAFT BEARING / OIL SEAL
REMOVAL
1) Remove drive shaft assembly.
Refer to item DRIVE SHAFT REMOVAL (LEFT and RIGHT) in
this section.
For right side shaft bearing / oil seal removal, drain differential
gear oil.
2) Remove left drive shaft by using tire lever.
3) Remove left side strut. Refer to steps 1) and 4) to 8) of item
STRUT DAMPER REMOVAL in Section 3D.
4) Remove oil seal, using plain screw driver.
5) Remove circlip.
6) Remove bearing, using special tools (A) and (B).
Special Tool
(A): 09941-64510
(B): 09930-30102

YH4
GRAND
VITARA
ªAº
1. Shaft bearing
1. Shaft oil seal
2. Right side
3. Left side
4A2-10 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
INSTALLATION
1) Clean drive shaft oil seal and then apply lithium grease.
ªAº: Grease 99000-25010
Check oil seal for breakage or deterioration.
Replace it as necessary.
2) Drive in drive shaft bearing with special tool (A) (on left hand
side).
Special Tool
(A): 09913-75520
3) Install circlip.
4) Drive in oil seal with special tools (B) and (C).
Special Tool
(B): 09951-16090
(C): 09924-74510
NOTE:
As depth to which oil seal should be driven into axle hous-
ing is different between the left and right, be sure to check
stamped marks on special tool (B) and drive each oil seal to
corresponding mark.
5) Install left drive shaft.
6) Install left side strut. Refer to steps 1) to 2) of item STRUT
DUMPER INSTALLATION in Section 3D.
7) Install drive shaft assembly.
Refer to DRIVE SHAFT INSTALLATION in this section.
8) Fill specified differential gear oil into differential case to specified
level.

YH4
GRAND
VITARA
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-11
09913-75520
Bearing installer09924-74510
Installer attachment09930-30102
Sliding shaft09941-64510
Bearing remover
09951-16090
Oil seal installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Drive shaft flange nut (Dif. side)505.036.5
Oil level plug232.317.0
Drain plug232.317.0
Axle shaft drive flange bolt484.835.0
NOTE:
Refer to standard tightening torque specifications, if no description or specification is provided.
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Joint grease
(Molybdenum grease)SUZUKI SUPER GREASE H
(99000-25120)Drive axle joint
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Drive shaft oil seal
Wheel spindle part of differential side
drive shaft (RH)
SealantSEALING COMPOUND 366E
(99000-31090)Axle shaft drive flange
SPECIAL TOOLS

YH4
GRAND
VITARA
4B
1. Front propeller shaft
(if equipped)
2. Rear propeller shaft
PROPELLER SHAFTS 4B-1
SECTION 4B
PROPELLER SHAFTS
NOTE:

All propeller shaft fasteners are an important attaching part in that it could affect the performance of vital
parts and systems, and / or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacement becomes necessary. Do not use a replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of this part.

Never attempt to heat, quench or straighten any propeller shaft part. Replace it with a new part, or dam-
age to the part may result.
CONTENTS
GENERAL DESCRIPTION4B- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS4B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table4B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Joint Check4B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE4B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft4B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATION4B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL4B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS4B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
Most universal joints require no maintenance. They are lubricated for life and can not be lubricated on the vehicle.
If a universal joint becomes noisy or worn, it must be replaced.
The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained.

YH4
GRAND
VITARA
4B-2 PROPELLER SHAFTS
DIAGNOSIS
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Abnormal noise
Loose universal joint bolt.

Spider bearing worn out or stuck.

Wear spider.Tighten universal joint bolt.
Replace.
Replace propeller shaft.
Vibration
Deformed propeller shaft.Replace.
PROPELLER SHAFT JOINT CHECK
If universal joints are suspected of producing chattering or rattling
noise, inspect them for wear. Check to see if cross spider rattles in
yokes or if splines are worn down and replace defective propeller
shaft with new one.
Noise coming from universal joint can be easily distinguished from
other noises because rhythm of chattering or rattling is in step with
cruising speed. Noise is pronounced particularly on standing start
or in coasting condition (when braking effect of engine is showing
in the drive line).