Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 241

3B-35 Differential: Rear

Tooth Contact Pattern

Diagnosis and Remedy

Normal

High Contact
Pinion is positioned too far from the center of drive 
bevel gear (1).
• Increase thickness of pinion (2) height adjusting 

shim and position pinion closer to gear center.

• Adjust drive bevel gear backlash to specification.

Low Contact
Pinion is positioned too close to the center of drive 
bevel gear (1).
• Decrease thickness of pinion (2) height adjusting 

shim and position pinion farther from gear center.

• Adjust drive bevel gear backlash to specification.

If adjustment is impossible, replace differential carrier.

• Check seating of bevel gear or differential case. (Check bevel 

gear for runout.)

• If adjustment is impossible, replace drive bevel gear and pinion 

set or differential carrier.

Replace drive bevel gear and pinion set or differential case.

I5JB0A321041-05

IYSQ01321072-01

IYSQ01321073-01

IYSQ01321074-01

IYSQ01321076-01

IYSQ01321077-01

IYSQ01321078-01

IYSQ01321079-01

Differential: Rear 3B-36

23) Upon completion of gear tooth contact check in Step 

22), caulk flange nut (2) with caulking tool (1) and 
hammer.

24) Clean mating surface of differential carrier (2) and 

rear cover (1), apply sealant to carrier as shown in 
figure by such amount that its section is 1.5 mm 
(0.059 in.) in diameter, mate rear cover with 
differential carrier, and then tighten bolts to specified 
torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Rear cover bolt No.1 (a):  50 N·m (5.0 kgf-m, 17.0 
lb-ft)
Rear cover bolt No.2 (b):  60 N·m (6.0 kgf-m, 43.5 
lb-ft)

25) Assembly rear drive right retainer as follows.

a) Install rear drive shaft bearing (1) using special 

tool and press (2).

Special tool
(A):  09913–75520 

b) Install snap ring.

c) Install oil seal using special tools as shown in 

figure.

Distance between retainer surface and oil 
seal
“a”: 2.5 – 3.0 mm (0.10 – 0.12 in.)

Special tool
(A):  09924–74510 
(B):  09951–16090 

I1JA01322021-01

(a)

1

2

(b)

2, “A”

I6JB01321001-03

2

(A)

1

I5JB0A322012-01

I5JB0A322010-01

I5JB0A322013-02

3B-37 Differential: Rear

26) Assembly rear drive left retainer in the same manner 

at Step 25) in this assembly procedure.

27) Clean mating surface of right retainer, carrier (1) and 

rear cover (2), apply sealant to carrier and rear cover 
as shown in figure by such amount that its section is 
1.5 mm (0.059 in.) in diameter, mate right retainer 
with carrier and rear cover, and then tighten bolts to 
specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Retainer bolt:  50 N·m (5.0 kgf-m, 36.5 lb-ft)

28) Clean mating surface of left retainer, carrier (1) and 

rear cover (2), apply sealant to carrier and rear cover 
as shown in figure by such amount that its section is 
1.5 mm (0.059 in.) in diameter, mate left retainer with 
carrier and rear cover, and then tighten bolts to 
specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G)

Tightening torque
Retainer bolt:  50 N·m (5.0 kgf-m, 36.5 lb-ft)

29) Install rear drive right and left shaft using plastic 

hammer.

Rear Differential Inspection

S6JB0A3226006

Refer to “Front Differential Inspection: Front”.

Specifications

Tightening Torque Specifications

S6JB0A3227001

NOTE
The specified tightening torque is also described in the following.
“Rear Differential Unit Components: Rear”
“Rear Differential Components: Rear”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

1

“A”

2

I5JB0A321048-01

“A”

2

1

I5JB0A322014-01

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Rear differential front mounting bolt

120

12.0 

87.0

)

Rear differential rear mounting bolt

120

12.0 

87.0

)

Bevel gear bolt

200

20.0 

145.0

)

Rear cover bolt No.1

50

5.0 

17.0

)

Rear cover bolt No.2

60

6.0 

43.5

)

Retainer bolt

50

5.0 

36.5

)

 / )

Differential: Rear 3B-38

Special Tools and Equipment

Recommended Service Material

S6JB0A3228001

NOTE
Required service material is also described in the following.
“Rear Differential Components: Rear”

 

Special Tool

S6JB0A3228002

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

Sealant

SUZUKI Bond No.1217G

P/No.: 99000–31260

)

 / ) / )

Thread lock cement

Thread Lock Cement Super 1322

P/No.: 99000–32110

)

09900–20607

09900–20701

Dial gauge

Magnetic stand

)

 / ) / ) / )

)

09913–50121

09913–65135

Oil seal remover

Bearing puller

)

 / )

)

 / )

09913–75510

09913–75520

Bearing installer

Bearing installer

)

)

09913–75821

09913–85210

Bearing installer attachment

Bearing installer

)

 / )

)

09922–66021

09922–75222

Flange holder

Differential gear preload 
adjuster

)

 / )

)

 / ) / )

09922–76520

09924–74510

Bevel pinion gauge block

Bearing and oil seal handle

)

 / )

)

 / )