Suzuki Grand Vitara JB627. Manual - part 140

 

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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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