Suzuki Grand Vitara JB416 / JB420. Manual — part 162
3B-1 Differential: Front
Driveline / Axle
Differential
Front
General Description
Front Differential Construction
S5JB0A3211001
The differential assembly uses a hypoid bevel pinion and gear.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and
specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between bevel pinion and
gear, it is mandatory to lubricate them by hypoid gear oil.
Diagnostic Information and Procedures
Front Differential Symptom Diagnosis
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Condition
Possible cause
Correction / Reference Item
Gear noise
Deteriorated or water mixed lubricant
Repair and replenish referring to “Front
Differential Oil Change: Front”.
Inadequate or insufficient lubricant
Repair and replenish referring to “Front
Differential Oil Change: Front”.
Maladjusted backlash between drive
bevel pinion and gear
Adjust as prescribed referring to “Front
Differential Assembly Disassembly and
Reassembly: Front”.
Improper tooth contact in the mesh
between drive bevel pinion and gear
Adjust or replace referring to “Front Differential
Assembly Disassembly and Reassembly:
Front”.
Loose drive bevel gear securing bolts
Replace or retighten referring to “Front
Differential Assembly Disassembly and
Reassembly: Front”.
Damaged differential gear(s) or
differential pinion(s)
Replace referring to “Front Differential
Inspection: Front”.
Bearing noise
(Constant noise) Deteriorated or water
mixed lubricant
Repair and replenish referring to “Front
Differential Oil Change: Front”.
(Constant noise) Inadequate or
insufficient lubricant
Repair and replenish referring to “Front
Differential Oil Change: Front”.
(Noise while coasting) Damaged
bearing(s) of drive bevel pinion
Replace referring to “Front Differential
Inspection: Front”.
(Noise while turning) Damaged
differential side bearing(s) or axle
bearing(s)
Replace referring to “Front Differential
Inspection: Front”.
Oil leakage
Clogged breather plug
Clean.
Worn or damaged oil seal
Replace.
Excessive oil
Adjust oil level referring to “Front Differential
Oil Change: Front”.
Loose differential carrier bolts
Replace or retighten.
Differential: Front 3B-2
Repair Instructions
Front Differential Oil Change
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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: 0.9 – 1.1 liters (1.9/1.6 – 2.3/1.9 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
3B-3 Differential: Front
Front Differential Unit Components
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Front Differential Dismounting and Remounting
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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
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
Differential: Front 3B-4
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
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(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
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