Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 233

3B-3 Differential: Front

Front Differential Unit Components

S6JB0A3216002

Front Differential Dismounting and Remounting

S6JB0A3216003

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).

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”.

2

1

3

7

(a)

5

(a)

(b)

8

(b)

4

(a)

5

(a)

6

I6JB0A321002-01

1. Front differential

5. Rear mounting bolt

: 85 N

⋅m (8.5 kgf-m, 61.5 lb-ft)

2. Right mounting bracket

6. Rear mounting bracket

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

3. Right mounting bolt

7. Right mounting bracket bolt

4. Differential mounting bolt

8. Rear mounting bracket bolt

1

1

2

I5JB0A321002-01

Differential: Front 3B-4

Front Differential Components

S6JB0A3216004

(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

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.

3B-5 Differential: Front

Front Differential Assembly Disassembly and
Reassembly

S6JB0A3216005

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

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

Differential: Front 3B-6

5) Support differential side right retainer (1) with soft

jawed vise and remove oil seal (2) from differential
side right retainer using special tool, if necessary.

Special tool
(A): 09913–50121

6) Take out differential assembly (1), outer race and

shim all at once.

7) Pull out differential side bearing (1) using special

tools.

Special tool
(A): 09913–65135
(B): 09925–86010

8) Remove drive bevel gear (hypoid gear), differential

gears, differential pinions and pinion shaft as follows.
a) With aluminum plates (2) placed on vise first,

grip differential case with it and remove drive
bevel gear (hypoid gear) (3) by removing its bolts
(1).

b) Remove pinion shaft (1), differential gears,

washers, differential pinions, spring washers and
thrust washers.

9) Remove drive bevel pinion (hypoid gear) assembly

as follows.
a) Hold joint flange with special tool and then

remove flange nut by using power wrench (4 –
10 magnification) (2).

Special tool
(A): 09922–66021

1

(A)

2

I5JB0A321011-01

1

I5JB0A321012-02

1

(B)

(A)

I5JB0A321013-02

1. Socket wrench

3

2

1

I5JB0A321014-02

1

I5JB0A321015-02

(A)

2

1

I5JB0A321016-02