Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 232

3A-8 Drive Shaft / Axle: Rear

Rear Drive Shaft Assembly Removal and 
Installation

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Removal

1) Undo caulking (1) of drive shaft nut (2) and then 

remove drive shaft nut.

2) Hoist vehicle and remove wheel.
3) Give match mark rear drive shaft flange (3) and rear 

drive shaft (4) as shown in figure, and then remove 
rear drive shaft flange nuts (1), and then remove rear 
drive shaft.

Installation
Install drive shaft assembly by reversing removal 
procedure and noting the following points.
• Install rear drive shaft (1) aligning match marks (2).

CAUTION

!

 

• Protect oil seals and boots from any 

damage, preventing them from 
unnecessary contact while installing drive 
shaft.

• Do not hit joint boot with hammer.

Inserting joint only by hands is allowed.

 

• Tighten each nuts to specified torque referring to 

“Rear Drive Shaft Components: Rear”.

Rear Drive Shaft Disassembly and Assembly

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Disassembly
Refer to “Front Drive Shaft Disassembly and Assembly: 
Front”.

Assembly
Assemble rear drive shaft assembly referring to “Front 
Drive Shaft Disassembly and Assembly: Front” and 
noting the following points which are different from that 
of the front drive shaft assembly.
• Apply grease to differential side joint.

Grease color
: Yellow

Amount
: 197 – 207 g (6.9 – 7.3 oz)

• Install tripod joint spider (1) on shaft by using special 

tool with hammer, directing its chamfered spline 
toward wheel side, and then fasten it with new snap 
ring (2) using snap ring plier (3).

Special tool
(A):  09913–84510

2. Match mark

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1

3

2

4

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2

1

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Drive Shaft / Axle: Rear 3A-9

Specifications

Tightening Torque Specifications

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

 

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

Special Tools and Equipment

Recommended Service Material

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

 

Special Tool

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09913–84510
Bearing installer
)

3B-1 Differential: Front

Driveline / Axle

Differential

Front

General Description

Front Differential Construction

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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 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)

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