Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 229

2D-9 Wheels and Tires:

Table of Contents 3- i

3

Section 3

CONTENTS

Driveline / Axle

Precautions . . . . . . . . . . . . .3-1

Precautions. . . . . . . . . . . . . . . . 3-1

Precautions for Driveline / Axle . . . . . . . . 3-1

Drive Shaft / Axle . . . . . . . . . . 3A-1

Front . . . . . . . . . . . . . . . . . . .3A-1

General Description . . . . . . . . . . . .3A-1

Front Drive Shaft Construction. . . . . . . 3A-1

Diagnostic Information and Procedures. . . 3A-1

Front Drive Shaft Symptom Diagnosis. . . . 3A-1

Repair Instructions . . . . . . . . . . . ..3A-2

Front Drive Shaft Boot and Joint Check. . . .. 3A-2
Front Drive Shaft Components . . . . . . ... 3A-2
Front Drive Shaft Assembly Removal and

Installation. . . . . . . . . . . . . . . 3A-3

Front Drive Shaft Disassembly and Assembly . 3A-3

Specifications. . . . . . . . . . . . . ...3A-6

Tightening Torque Specifications. . . . . . 3A-6

Special Tools and Equipment . . . . . . . .3A-6

Recommended Service Material. . . . . . . 3A-6
Special Tool . . . . . . . . . . . . . . 3A-6

Rear . . . . . . . . . . . . . . . . . . ..3A-7

General Description . . . . . . . . . . . .3A-7

Rear Drive Shaft Construction . . . . . . . 3A-7

Repair Instructions . . . . . . . . . . . ..3A-7

Rear Drive Shaft Components . . . . . . . 3A-7
Rear Drive Shaft Assembly Removal and

Installation. . . . . . . . . . . . . . . 3A-8

Rear Drive Shaft Disassembly and Assembly. . 3A-8

Specifications. . . . . . . . . . . . . ...3A-9

Tightening Torque Specifications. . . . . . 3A-9

Special Tools and Equipment . . . . . . . .3A-9

Recommended Service Material. . . . . . . 3A-9
Special Tool . . . . . . . . . . . . . . 3A-9

Differential. . . . . . . . . . . . 3B-1

Front . . . . . . . . . . . . . . . . . . .3B-1

General Description . . . . . . . . . . . .3B-1

Front Differential Construction . . . . . . . 3B-1

Diagnostic Information and Procedures. . . 3B-1

Front Differential Symptom Diagnosis. . . . . 3B-1

Repair Instructions . . . . . . . . . . . ..3B-2

Front Differential Oil Change . . . . . . . .. 3B-2

Front Differential Unit Components. . . . . .3B-3
Front Differential Dismounting and

Remounting. . . . . . . . . . . . . ...3B-3

Front Differential Components . . . . . . . 3B-4
Front Differential Assembly Disassembly and

Reassembly . . . . . . . . . . . . . ..3B-5

Front Differential Inspection . . . . . . . ..3B-18

Specifications. . . . . . . . . . . . . .3B-18

Tightening Torque Specifications. . . . . ..3B-18

Special Tools and Equipment . . . . . . ...3B-18

Recommended Service Material . . . . . ...3B-18
Special Tool . . . . . . . . . . . . . ..3B-18

Rear . . . . . . . . . . . . . . . . . . 3B-21

General Description . . . . . . . . . . ...3B-21

Rear Differential Construction . . . . . . ...3B-21

Diagnostic Information and Procedures. . ..3B-21

Rear Differential Symptom Diagnosis . . . ...3B-21

Repair Instructions . . . . . . . . . . . 3B-21

Rear Differential Oil Change . . . . . . . .3B-21
Rear Differential Unit Components . . . . ...3B-22
Rear Differential Dismounting and

Remounting. . . . . . . . . . . . . .3B-22

Rear Differential Components. . . . . . ...3B-24
Rear Differential Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3B-25

Rear Differential Inspection. . . . . . . ...3B-37

Specifications. . . . . . . . . . . . . .3B-37

Tightening Torque Specifications. . . . . ..3B-37

Special Tools and Equipment . . . . . . ...3B-38

Recommended Service Material . . . . . ...3B-38
Special Tool . . . . . . . . . . . . . ..3B-38

Transfer . . . . . . . . . . . . . 3C-1

Motor-Shift Type (Transfer with Shift

Actuator) . . . . . . . . . . . . . . . . 3C-1

Precautions. . . . . . . . . . . . . . ...3C-1

Transfer Warning . . . . . . . . . . . . 3C-1
Precautions in Diagnosing Trouble . . . . . .3C-1

General Description . . . . . . . . . . . .3C-2

Transfer Description. . . . . . . . . . . 3C-2
4WD Control System Description. . . . . . 3C-3
Function of 4WD Control System Component . 3C-5
4WD Control System Operation. . . . . . ..3C-5

3-ii Table of Contents

Input / Output Signal Table of 4WD Control

Module . . . . . . . . . . . . . . . 3C-10

On-Board Diagnostic System Description. . .3C-11
CAN Communication System Description. . .3C-12

Schematic and Routing Diagram. . . . . ..3C-13

4WD Control System Wiring Circuit Diagram. 3C-13

Component Location . . . . . . . . . . .3C-15

Transfer Shift Control System Components

Location . . . . . . . . . . . . . . ..3C-15

Diagnostic Information and Procedures. . ..3C-16

4WD Control System Check . . . . . . . .3C-16
Transfer Position Indicator Operation Check . 3C-18
4WD Control System Operation Inspection . ..3C-18
Visual Inspection . . . . . . . . . . . ...3C-20
DTC Check. . . . . . . . . . . . . . 3C-20
DTC Clearance . . . . . . . . . . . . .3C-21
DTC Table. . . . . . . . . . . . . . .3C-22
Fail-Safe Table. . . . . . . . . . . . ..3C-23
Scan Tool Data . . . . . . . . . . . . .3C-23
Scan Tool Data Definitions. . . . . . . . 3C-24
4WD Control Symptom Diagnosis. . . . . .3C-25
Transfer Position Indicator Does Not Come

ON at Ignition Switch ON but Engine Stops. 3C-27

Transfer Position Indicator Remains ON

Steady at Ignition Switch ON . . . . . . ..3C-29

DTC C1213: Transfer Switch Circuit Open . ...3C-30
DTC C1214: Transfer Switch Circuit Short . ...3C-31
DTC C1223 / C1235: Transfer Shift Actuator

Motor Position Switch 1 Circuit Open /
Transfer Shift Actuator Motor Position
Switch 2 Circuit Open . . . . . . . . . .3C-33

DTC C1224 / C1236: Transfer Shift Actuator

Motor Position Switch 1 Circuit Short /
Transfer Shift Actuator Motor Position
Switch 2 Circuit Short. . . . . . . . . ..3C-35

DTC C1227: 4L/N Switch Circuit Open . . . .3C-37
DTC C1228: 4L/N Switch Circuit Short . . . .3C-38
DTC C1230: Transfer Actuator Circuit

Malfunction. . . . . . . . . . . . . ..3C-40

DTC C1237: Center Differential Lock Switch

Circuit Open . . . . . . . . . . . . . 3C-42

DTC C1238: Center Differential Lock Switch

Circuit Short . . . . . . . . . . . . . 3C-43

DTC C1240: 4WD Control Module Power

Supply Circuit Malfunction . . . . . . . ..3C-45

DTC C1243: Internal Circuit Malfunction of

4WD Control Module. . . . . . . . . ...3C-46

DTC C1246: Clutch Pedal Position (CPP)

Switch Circuit Short. . . . . . . . . . .3C-46

DTC U1073: Control Module Communication

Buss Off . . . . . . . . . . . . . . ..3C-48

DTC U1100: Lost Communication with ECM . 3C-50
DTC U1121: Lost Communication with ABS /

Electronic Stability Program Hydraulic Unit /
Control Module. . . . . . . . . . . . 3C-51

Inspection of 4WD Control Module and Its

Circuits . . . . . . . . . . . . . . . 3C-52

Repair Instructions . . . . . . . . . . . 3C-55

Transfer Oil Level Check. . . . . . . . ...3C-55

Transfer Oil Change. . . . . . . . . . ..3C-55
Transfer Oil Seal Removal and Installation. ...3C-56
Transfer Switch Removal and Installation. . .3C-56
Transfer Switch Inspection. . . . . . . . 3C-57
4WD Control Module Removal and

Installation . . . . . . . . . . . . . ...3C-57

Transfer Assembly Dismounting and

Remounting. . . . . . . . . . . . . .3C-58

Transfer Assembly Components. . . . . ...3C-59
Transfer Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-60

Transfer Assembly Inspection. . . . . . ...3C-69
Input Gear Assembly, Counter Gear

Assembly, Front Output Shaft Assembly and
Rear Output Shaft Assembly Components . .3C-71

Input Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-71

Counter Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-72

Front Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-73

Rear Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-74

Specifications . . . . . . . . . . . . . .3C-75

Tightening Torque Specifications. . . . . ..3C-75

Special Tools and Equipment . . . . . . ...3C-75

Recommended Service Material . . . . . ...3C-75
Special Tool . . . . . . . . . . . . . ..3C-76

Non-Shift Type (Transfer without Shift

Actuator) . . . . . . . . . . . . . . . ..3C-77

Precautions. . . . . . . . . . . . . . .3C-77

Transfer Warning . . . . . . . . . . . ..3C-77

General Description . . . . . . . . . . ...3C-77

Transfer Construction. . . . . . . . . . 3C-77

Diagnostic Information and Procedures . . ..3C-78

Transfer Symptom Diagnosis. . . . . . . 3C-78

Repair Instructions . . . . . . . . . . . 3C-79

Transfer Oil Change. . . . . . . . . . ..3C-79
Transfer Oil Level Check. . . . . . . . ...3C-79
Transfer Oil Seal Removal and Installation. ...3C-79
Transfer Assembly Dismounting and

Remounting. . . . . . . . . . . . . .3C-79

Transfer Assembly Components. . . . . ...3C-80
Transfer Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-81

Input Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-88

Front Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-88

Rear Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-88

Specifications . . . . . . . . . . . . . .3C-89

Tightening Torque Specifications. . . . . ..3C-89

Special Tools and Equipment . . . . . . ...3C-89

Recommended Service Material . . . . . ...3C-89
Special Tool . . . . . . . . . . . . . ..3C-89

Propeller Shaft . . . . . . . . . . . 3D-1

Precautions. . . . . . . . . . . . . . ...3D-1

Table of Contents 3-iii

Propeller Shaft Caution. . . . . . . . . ...3D-1

General Description . . . . . . . . . . . .3D-1

Propeller Shaft Construction . . . . . . . ...3D-1

Diagnostic Information and Procedures. . . 3D-2

Propeller Shaft Symptom Diagnosis . . . . ...3D-2

Repair Instructions . . . . . . . . . . . ..3D-2

Propeller Shaft Joint Check . . . . . . . . 3D-2
Propeller Shaft Removal and Installation. . . 3D-2

Propeller Shaft Disassembly and Assembly . ...3D-3
Propeller Shaft Inspection . . . . . . . . ...3D-5

Specifications. . . . . . . . . . . . . ...3D-6

Tightening Torque Specifications. . . . . . 3D-6

Special Tools and Equipment . . . . . . . .3D-6

Recommended Service Material . . . . . . .3D-6
Special Tool . . . . . . . . . . . . . . 3D-6