Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 236
3B-15 Differential: Front
Tooth Contact Pattern
Diagnosis and Remedy
Normal
High Contact
Pinion is positioned too far from the center of drive
bevel gear (1).
• Increase thickness of pinion (2) height adjusting
shim and position pinion closer to gear center.
• Adjust drive bevel gear backlash to specification.
Low Contact
Pinion is positioned too close to the center of drive
bevel gear (1).
• Decrease thickness of pinion (2) height adjusting
shim and position pinion farther from gear center.
• Adjust drive bevel gear backlash to specification.
If adjustment is impossible, replace differential carrier.
• Check seating of bevel gear or differential case. (Check bevel
gear for runout.)
• If adjustment is impossible, replace drive bevel gear and pinion
set or differential carrier.
Replace drive bevel gear and pinion set or differential case.
I5JB0A321041-05
IYSQ01321072-01
IYSQ01321073-01
IYSQ01321074-01
IYSQ01321076-01
IYSQ01321077-01
IYSQ01321078-01
IYSQ01321079-01
Differential: Front 3B-16
23) Upon completion of gear tooth contact check in Step
22), caulk flange nut (2) with caulking tool (1) and
hammer.
24) Clean mating surface of differential carrier (2) and
rear cover (1), apply sealant to carrier as shown in
figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate rear cover with
differential carrier, and then tighten bolts to specified
torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Rear cover bolt No.1 (a): 50 N·m (5.0 kgf-m, 36.5
lb-ft)
Rear cover bolt No.2 (b): 60 N·m (6.0 kgf-m, 43.5
lb-ft)
25) Assembly front drive shaft retainer as follows.
a) Install front drive shaft bearing (1) using special
tool, and then install snap ring.
Special tool
(A): 09913–75520
b) Apply grease to oil seal lip, and then install oil
seal (1) using special tools as shown in figure.
Distance between retainer surface and oil
seal
“a”: 4.7 – 5.2 mm (0.185 – 0.205 in.)
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Special tool
(A): 09924–74510
(B): 09951–16090
I1JA01322021-01
(a)
1
2
(b)
2, “A”
I6JB01321001-03
(A)
1
I5JB0A321043-01
I5JB0A321044-01
3B-17 Differential: Front
26) Apply grease to oil seal lip, and then install oil seal
into differential side right retainer (1) as shown in
figure.
Distance between retainer surface and oil seal
“a”: 0.65 – 1.65 mm (0.026 – 0.065 in.)
“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Special tool
(A): 09913–75520
27) Clean mating surface of right retainer, carrier (1) and
rear cover (2), apply sealant to carrier and rear cover
as shown in figure by such amount that its section is
1.5 mm (0.059 in.) in diameter, mate right retainer
with carrier and rear cover, and then tighten bolts to
specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Retainer bolt: 50 N·m (5.0 kgf-m, 36.5 lb-ft)
28) Clean mating surface of front drive shaft retainer,
carrier (1) and rear cover (2), apply sealant to carrier
and rear cover as shown in figure by such amount
that its section is 1.5 mm (0.059 in.) in diameter,
mate front drive shaft retainer with carrier and rear
cover, and then tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Retainer bolt: 50 N·m (5.0 kgf-m, 36.5 lb-ft)
29) Install front drive shaft using plastic hammer.
30) Install front differential rear mounting (1).
Tightening torque
Rear mounting bracket bolt (a): 50 N·m (5.0 kgf-
m, 36.5 lb-ft)
31) Install front differential right mounting (1).
Tightening torque
Right mounting bracket bolt (b): 50 N·m (5.0 kgf-
m, 36.5 lb-ft)
I5JB0A321045-01
1
“A”
2
I5JB0A321048-01
“A”
2
1
I5JB0A322014-01
(a)
1
I5JB0A321046-01
1
(b)
I5JB0A321047-02
Differential: Front 3B-18
Front Differential Inspection
S6JB0A3216006
• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.
• Check drive bevel pinion and drive bevel gear for
wear or cracks.
• Check differential gears, pinions and pinion shafts for
wear or damage.
• Check differential gear spline for wear or damage.
Specifications
Tightening Torque Specifications
S6JB0A3217001
NOTE
The specified tightening torque is also described in the following.
“Front Differential Unit Components: Front”
“Front Differential Components: Front”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.
Special Tools and Equipment
Recommended Service Material
S6JB0A3218001
NOTE
Required service material is also described in the following.
“Front Differential Components: Front”
Special Tool
S6JB0A3218002
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Differential oil drain plug
23
2.3
17.0
Differential oil level / filler plug
23
2.3
17.0
Bevel gear bolt
Tighten 40 N
⋅m (4.0 kgf-m, 29.5 lb-ft) + 50° )
Rear cover bolt No.1
50
5.0
36.5
Rear cover bolt No.2
60
6.0
43.5
Retainer bolt
50
5.0
36.5
Rear mounting bracket bolt
50
5.0
36.5
Right mounting bracket bolt
50
5.0
36.5
Material
SUZUKI recommended product or Specification
Note
Grease
SUZUKI Super Grease A
P/No.: 99000–25010
Sealant
SUZUKI Bond No.1217G
P/No.: 99000–31260
Thread lock cement
Thread Lock Cement Super 1322
P/No.: 99000–32110
09900–20607
09900–20701
Dial gauge
Magnetic stand
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