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