Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 229

2D-9 Wheels and Tires: 

Table of Contents 3- i

3

Section 3

CONTENTS

Driveline / Axle

Precautions .................................................3-1

Precautions............................................................. 3-1

Precautions for Driveline / Axle ............................. 3-1

Drive Shaft / Axle ..................................... 3A-1

Front .........................................................................3A-1

General Description .............................................3A-1

Front Drive Shaft Construction............................ 3A-1

Diagnostic Information and Procedures............3A-1

Front Drive Shaft Symptom Diagnosis................ 3A-1

Repair Instructions ..............................................3A-2

Front Drive Shaft Boot and Joint Check.............. 3A-2
Front Drive Shaft Components ........................... 3A-2
Front Drive Shaft Assembly Removal and 

Installation......................................................... 3A-3

Front Drive Shaft Disassembly and Assembly .... 3A-3

Specifications.......................................................3A-6

Tightening Torque Specifications........................ 3A-6

Special Tools and Equipment .............................3A-6

Recommended Service Material......................... 3A-6
Special Tool ........................................................ 3A-6

Rear ..........................................................................3A-7

General Description .............................................3A-7

Rear Drive Shaft Construction ............................ 3A-7

Repair Instructions ..............................................3A-7

Rear Drive Shaft Components ............................ 3A-7
Rear Drive Shaft Assembly Removal and 

Installation......................................................... 3A-8

Rear Drive Shaft Disassembly and Assembly..... 3A-8

Specifications.......................................................3A-9

Tightening Torque Specifications........................ 3A-9

Special Tools and Equipment .............................3A-9

Recommended Service Material......................... 3A-9
Special Tool ........................................................ 3A-9

Differential................................................ 3B-1

Front .........................................................................3B-1

General Description .............................................3B-1

Front Differential Construction ............................ 3B-1

Diagnostic Information and Procedures............3B-1

Front Differential Symptom Diagnosis................. 3B-1

Repair Instructions ..............................................3B-2

Front Differential Oil Change .............................. 3B-2

Front Differential Unit Components.....................3B-3
Front Differential Dismounting and 

Remounting.......................................................3B-3

Front Differential Components ............................3B-4
Front Differential Assembly Disassembly and 

Reassembly ......................................................3B-5

Front Differential Inspection ..............................3B-18

Specifications.....................................................3B-18

Tightening Torque Specifications......................3B-18

Special Tools and Equipment ...........................3B-18

Recommended Service Material .......................3B-18
Special Tool ......................................................3B-18

Rear ........................................................................3B-21

General Description ...........................................3B-21

Rear Differential Construction ...........................3B-21

Diagnostic Information and Procedures..........3B-21

Rear Differential Symptom Diagnosis ...............3B-21

Repair Instructions ............................................3B-21

Rear Differential Oil Change .............................3B-21
Rear Differential Unit Components ...................3B-22
Rear Differential Dismounting and 

Remounting.....................................................3B-22

Rear Differential Components...........................3B-24
Rear Differential Assembly Disassembly and 

Reassembly ....................................................3B-25

Rear Differential Inspection...............................3B-37

Specifications.....................................................3B-37

Tightening Torque Specifications......................3B-37

Special Tools and Equipment ...........................3B-38

Recommended Service Material .......................3B-38
Special Tool ......................................................3B-38

Transfer .................................................... 3C-1

Motor-Shift Type (Transfer with Shift 

Actuator) ................................................................3C-1

Precautions...........................................................3C-1

Transfer Warning ................................................3C-1
Precautions in Diagnosing Trouble .....................3C-1

General Description .............................................3C-2

Transfer Description............................................3C-2
4WD Control System Description........................3C-3
Function of 4WD Control System Component ....3C-5
4WD Control System Operation..........................3C-5

3-ii Table of Contents

Input / Output Signal Table of 4WD Control 

Module ............................................................3C-10

On-Board Diagnostic System Description.........3C-11
CAN Communication System Description.........3C-12

Schematic and Routing Diagram......................3C-13

4WD Control System Wiring Circuit Diagram....3C-13

Component Location .........................................3C-15

Transfer Shift Control System Components 

Location ..........................................................3C-15

Diagnostic Information and Procedures..........3C-16

4WD Control System Check .............................3C-16
Transfer Position Indicator Operation Check ....3C-18
4WD Control System Operation Inspection ......3C-18
Visual Inspection ...............................................3C-20
DTC Check........................................................3C-20
DTC Clearance .................................................3C-21
DTC Table.........................................................3C-22
Fail-Safe Table..................................................3C-23
Scan Tool Data .................................................3C-23
Scan Tool Data Definitions................................3C-24
4WD Control Symptom Diagnosis.....................3C-25
Transfer Position Indicator Does Not Come 

ON at Ignition Switch ON but Engine Stops....3C-27

Transfer Position Indicator Remains ON 

Steady at Ignition Switch ON ..........................3C-29

DTC C1213: Transfer Switch Circuit Open .......3C-30
DTC C1214: Transfer Switch Circuit Short .......3C-31
DTC C1223 / C1235: Transfer Shift Actuator 

Motor Position Switch 1 Circuit Open / 
Transfer Shift Actuator Motor Position 
Switch 2 Circuit Open .....................................3C-33

DTC C1224 / C1236: Transfer Shift Actuator 

Motor Position Switch 1 Circuit Short / 
Transfer Shift Actuator Motor Position 
Switch 2 Circuit Short......................................3C-35

DTC C1227: 4L/N Switch Circuit Open .............3C-37
DTC C1228: 4L/N Switch Circuit Short .............3C-38
DTC C1230: Transfer Actuator Circuit 

Malfunction......................................................3C-40

DTC C1237: Center Differential Lock Switch 

Circuit Open ....................................................3C-42

DTC C1238: Center Differential Lock Switch 

Circuit Short ....................................................3C-43

DTC C1240: 4WD Control Module Power 

Supply Circuit Malfunction ..............................3C-45

DTC C1243: Internal Circuit Malfunction of 

4WD Control Module.......................................3C-46

DTC C1246: Clutch Pedal Position (CPP) 

Switch Circuit Short.........................................3C-46

DTC U1073: Control Module Communication 

Buss Off ..........................................................3C-48

DTC U1100: Lost Communication with ECM ....3C-50
DTC U1121: Lost Communication with ABS / 

Electronic Stability Program Hydraulic Unit / 
Control Module................................................3C-51

Inspection of 4WD Control Module and Its 

Circuits ............................................................3C-52

Repair Instructions ............................................3C-55

Transfer Oil Level Check...................................3C-55

Transfer Oil Change..........................................3C-55
Transfer Oil Seal Removal and Installation.......3C-56
Transfer Switch Removal and Installation.........3C-56
Transfer Switch Inspection................................3C-57
4WD Control Module Removal and 

Installation .......................................................3C-57

Transfer Assembly Dismounting and 

Remounting.....................................................3C-58

Transfer Assembly Components.......................3C-59
Transfer Assembly Disassembly and 

Reassembly ....................................................3C-60

Transfer Assembly Inspection...........................3C-69
Input Gear Assembly, Counter Gear 

Assembly, Front Output Shaft Assembly and 
Rear Output Shaft Assembly Components .....3C-71

Input Gear Assembly Disassembly and 

Reassembly ....................................................3C-71

Counter Gear Assembly Disassembly and 

Reassembly ....................................................3C-72

Front Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-73

Rear Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-74

Specifications .....................................................3C-75

Tightening Torque Specifications......................3C-75

Special Tools and Equipment ...........................3C-75

Recommended Service Material .......................3C-75
Special Tool ......................................................3C-76

Non-Shift Type (Transfer without Shift 

Actuator) ..............................................................3C-77

Precautions.........................................................3C-77

Transfer Warning ..............................................3C-77

General Description ...........................................3C-77

Transfer Construction........................................3C-77

Diagnostic Information and Procedures ..........3C-78

Transfer Symptom Diagnosis............................3C-78

Repair Instructions ............................................3C-79

Transfer Oil Change..........................................3C-79
Transfer Oil Level Check...................................3C-79
Transfer Oil Seal Removal and Installation.......3C-79
Transfer Assembly Dismounting and 

Remounting.....................................................3C-79

Transfer Assembly Components.......................3C-80
Transfer Assembly Disassembly and 

Reassembly ....................................................3C-81

Input Gear Assembly Disassembly and 

Reassembly ....................................................3C-88

Front Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-88

Rear Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-88

Specifications .....................................................3C-89

Tightening Torque Specifications......................3C-89

Special Tools and Equipment ...........................3C-89

Recommended Service Material .......................3C-89
Special Tool ......................................................3C-89

Propeller Shaft ......................................... 3D-1

Precautions...........................................................3D-1

Table of Contents 3-iii

Propeller Shaft Caution.......................................3D-1

General Description .............................................3D-1

Propeller Shaft Construction ...............................3D-1

Diagnostic Information and Procedures............3D-2

Propeller Shaft Symptom Diagnosis ...................3D-2

Repair Instructions ..............................................3D-2

Propeller Shaft Joint Check ................................3D-2
Propeller Shaft Removal and Installation............3D-2

Propeller Shaft Disassembly and Assembly .......3D-3
Propeller Shaft Inspection ...................................3D-5

Specifications.......................................................3D-6

Tightening Torque Specifications........................3D-6

Special Tools and Equipment .............................3D-6

Recommended Service Material .........................3D-6
Special Tool ........................................................3D-6