Suzuki Grand Vitara JB627. Manual — part 140
3B-2 Differential: Front
Repair Instructions
Front Differential Oil Change
S6JB0B3216001
1) Before changing or inspecting oil, be sure to stop
engine and lift vehicle horizontally.
2) With vehicle lifted up, check leakage.
If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.
3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil.
5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential oil drain plug (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
6) Pour new specified oil until oil level reaches bottom
of oil filler plug hole (3) as shown in figure.
NOTE
• Hypoid gear oil must be used for
differential.
• It is highly recommended to use API GL-5
80W-90 gear oil.
Differential oil specification
: API GL-5 (For SAE classification, refer to
viscosity chart [A] in figure.)
Front differential oil capacity
Reference: 0.85 – 1.05 liters (1.8/1.5 – 2.2/1.8 US/
Imp. pt.)
7) Apply sealant to thread of level / filler plug, and then
tighten it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential oil level / filler plug (b): 23 N·m (2.3
kgf-m, 17.0 lb-ft)
I5JB0A321004-02
Differential: Front 3B-3
Front Differential Unit Components
S6JB0B3216002
Front Differential Dismounting and Remounting
S6JB0B3216003
Dismounting
1) Lift up vehicle and drain front differential oil.
2) Remove front drive shafts referring to “Front Drive
Shaft Assembly Removal and Installation: Front in
Section 3A”.
3) Remove front suspension frame with front differential
referring to “Front Suspension Frame, Stabilizer Bar
and/or Bushings Removal and Installation in Section
2B”.
4) Remove mounting bolts (1), and then take off front
differential from front suspension frame (2).
2
1
3
7
(a)
5
(a)
(b)
8
6
(b)
4
(a)
5
(a)
10
(c)
9
I5JB0A321001-05
1. Front differential
8. Rear mounting bracket bolt
2. Right mounting bracket
9. Damper
3. Right mounting bolt
10. Damper bolt
4. Differential mounting bolt
: 85 N
⋅m (8.5 kgf-m, 61.5 lb-ft)
5. Rear mounting bolt
: 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
6. Rear mounting bracket
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Right mounting bracket bolt
1
1
2
I5JB0A321002-01
3B-4 Differential: Front
Remounting
Reverse dismounting procedure for remounting noting the following.
• Tighten each bolts and nuts referring to “Front Differential Unit Components: Front”, “Front Drive Shaft Components:
Front in Section 3A” and “Front Suspension Frame, Stabilizer Bar and/or Bushings Components in Section 2B”.
• Fill front differential oil referring to “Front Differential Oil Change: Front”.
Front Differential Components
S6JB0B3216004
(a)
18
(a)
18
(b)
24
19
9
21
15
14
16
17
14
10
11
11
17
16
5
26
2
4
13
23
12
10
(c)
22
3
6
7
1
A
8
(a)
25
15
20
20
I5JB0A321003-08
1. Universal joint flange
17. Pinion washer
2. Hypoid gear set
18. Retainer bolt
3. Bevel pinion spacer
19. Differential side right retainer
: Apply sealant 99000-31260 to mating surface of right retainer,
carrier and rear cover.
4. Shim
20. Shim
5. Rear bearing
21. Front drive shaft retainer
: Apply sealant 99000-31260 to mating surface of drive shaft
retainer, carrier and rear cover.
6. Front bearing
22. Bevel gear bolt
: Apply thread lock cement 99000-32110 to thread part of bolt.
7. Oil seal
: Apply grease 99000-25010 to oil seal lip.
23. Rear cover
8. Flange nut
: After tightening nut so as rotation torque of bevel pinion shaft to be
in specified value, caulk nut securely.
24. Rear cover bolt No.2 bolt
Differential: Front 3B-5
Front Differential Assembly Disassembly and
Reassembly
S6JB0B3216005
Disassembly
1) Remove front differential right mounting (1) and rear
mounting (2).
2) Drive out front drive shaft (1) from front shaft retainer
(2) using plastic hammer (3).
3) Remove differential side right retainer and front drive
shaft retainer, and then remove rear cover (1).
4) Disassembly front drive shaft retainer as follows, if
necessary.
a) Remove oil seal (1) from front drive shaft retainer
using special tool.
Special tool
(A): 09913–50121
b) Remove snap ring (1) using snap ring plier.
c) Drive out front drive shaft bearing using special
tools.
Special tool
(A): 09930–30104
(B): 09941–64511
9. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear
cover.
25. Rear cover bolt No.1 bolt
10. Differential pinion
26. Differential right case
11. Differential gear
: 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
12. Pinion shaft
: 60 N
⋅m (6.0 kgf-m, 43.5 lb-ft)
13. Differential left case
: 40 N
⋅m (4.0 kgf-m, 29.5 lb-ft) + 50°
14. Thrust washer
: Do not reuse.
15. Differential side bearing
: Apply differential oil.
16. Spring washer
1
2
I5JB0A321005-01
I5JB0A321006-01
1
I5JB0A321007-01
1
(A)
I5JB0A321008-01
1
I5JB0A321009-01
(B)
(A)
I5JB0A321010-01
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