Suzuki Grand Vitara JB416 / JB420. Manual - part 162

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 or inspecting 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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3B-3 Differential: Front

Front Differential Unit Components

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Front Differential Dismounting and Remounting

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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).

2

1

3

7

(a)

5

(a)

(b)

8

6

(b)

4

(a)

5

(a)

10

(c)

9

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1. Front differential

8. Rear mounting bracket bolt

2. Right mounting bracket

9. Damper

3. Right mounting bolt

10. Damper bolt

4. Differential mounting bolt

: 85 N

⋅m (8.5 kgf-m, 61.5 lb-ft)

5. Rear mounting bolt

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

6. Rear mounting bracket

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

7. Right mounting bracket bolt

1

1

2

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Differential: Front 3B-4

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”.

Front Differential Components

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(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

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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