Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 236

3B-15 Differential: Front

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: Front 3B-16

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, 36.5 
lb-ft)
Rear cover bolt No.2 (b):  60 N·m (6.0 kgf-m, 43.5 
lb-ft)

25) Assembly front drive shaft retainer as follows.

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

tool, and then install snap ring.

Special tool
(A):  09913–75520

b) Apply grease to oil seal lip, and then install oil 

seal (1) using special tools as shown in figure.

Distance between retainer surface and oil 
seal
“a”: 4.7 – 5.2 mm (0.185 – 0.205 in.)

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)

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

I1JA01322021-01

(a)

1

2

(b)

2, “A”

I6JB01321001-03

(A)

1

I5JB0A321043-01

I5JB0A321044-01

3B-17 Differential: Front

26) Apply grease to oil seal lip, and then install oil seal 

into differential side right retainer (1) as shown in 
figure.

Distance between retainer surface and oil seal
“a”: 0.65 – 1.65 mm (0.026 – 0.065 in.)

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A)

Special tool
(A):  09913–75520

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 front drive shaft 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 front drive shaft 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 front drive shaft using plastic hammer.
30) Install front differential rear mounting (1).

Tightening torque
Rear mounting bracket bolt (a):  50 N·m (5.0 kgf-
m, 36.5 lb-ft)

31) Install front differential right mounting (1).

Tightening torque
Right mounting bracket bolt (b):  50 N·m (5.0 kgf-
m, 36.5 lb-ft)

I5JB0A321045-01

1

“A”

2

I5JB0A321048-01

“A”

2

1

I5JB0A322014-01

(a)

1

I5JB0A321046-01

1

(b)

I5JB0A321047-02

Differential: Front 3B-18

Front Differential Inspection

S6JB0A3216006

• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.

• Check drive bevel pinion and drive bevel gear for 

wear or cracks.

• Check differential gears, pinions and pinion shafts for 

wear or damage.

• Check differential gear spline for wear or damage.

Specifications

Tightening Torque Specifications

S6JB0A3217001

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

 

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

S6JB0A3218001

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

 

Special Tool

S6JB0A3218002

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Differential oil drain plug

23

2.3 

17.0

)

Differential oil level / filler plug

23

2.3 

17.0

)

Bevel gear bolt

Tighten 40 N

⋅m (4.0 kgf-m, 29.5 lb-ft) + 50°  )

Rear cover bolt No.1

50

5.0 

36.5

)

Rear cover bolt No.2

60

6.0 

43.5

)

Retainer bolt

50

5.0 

36.5

)

 / )

Rear mounting bracket bolt

50

5.0 

36.5

)

Right mounting bracket bolt

50

5.0 

36.5

)

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

)

 / ) / ) / )

)