Suzuki VITARA 1993 Manual

suzl,t<r

Caring for Customers

99501-60A31-34E

(r)

FOREWORD

This SUPPLEMENTARY SERVICE MANUAL

is a supplement to "VITARA SERVICE MAN-

UAL".

It describes LSD (Limited Slip Differential)

service information of VITARA.

Whenever servicing (disassembling, inspecting

and/or reassembling) LSD, consult this supple

ment. For its removal and installation, refer to

"v TTARA SE RV tCE MAN UAL" (99500_60A1 O).

All information, illustrations and specifications

contained in this literature are based on thelatest

product information available at ttle tinre of

publication approval. The right is resrrcd to

make changes at any time withqrt notice.

Asterisk (*) marked cotrpGls h fte Ext are

applicable to the LSD irtJH to uetricles on

and after fdbrhgbody nrr$rs.

8.lsaeraorunrrtEt i-

8saeroolunrl3gs) 8-

l'zsgrRorcflxE2t32i v -

SUZUK! TOTOR qORPORAfIOil

AUTOMOBILE DEPARTMENT

OVE R SEAS SE R VICE D I V ISI O N

TABLE OF CONTENTS

TRANS.

Differential (LSD, Rear)

O COPYRIGHT SUZUKI MOTOR CORPORATION 1993

DIFFERENTIAL 7E.1

SECTION 7E

DIFFERENTIAL (LSD, REAR)

NOTE:

This section provides information necessary for servicing LSD (Limited Slip Differential), namely, general

d iscription, maintenance, d isassembly, i nspection and reassem bly.

For any other service information not found here, refer to "VITARA SERVICE MANUAL".

CONTENTS

GENERALDESCRIPTION .,,,,.7E-1

ONVEHICLESERVICE ... .,.,,7E.3

MaintenanceService ..,.7E-3

UNIT REPAIR OVERHALL .. ,.,7E-3

LIMITED SLIP DIFFERENTIAL

(LSD) ,, ,.,7E.3

DismountinS.... ,.....7E-3

Disassembling ... ......7E-3

GENERAL

LS D has a lim itei s 'o ce ", .? -:: -:: -::?- - :

as its name indicates. ln ac:::^:l:-:.--:::-

as an ordinary differentiail to a c,,. :":: - l-: a-:

left wheels to roiate cy differer-t i-o--tS ,,, -€n

turns are made. it hasanotherfunctic". ,\-en rne

wheel on one side starts slippirg : :revents

such slip.

Its components are sho,,,,,n ln Fic. lI-1.

lnspecting of LSD Case Assembly . . . 7E- 3

Disassembling of LSD Case Assembly. . 7E- 4

lnspecting of LSD Case Component

Parts . 7E- s

Reassembling of LSD Case Assembly , , 7E- 7

Adjustment and Reassembly . .7E-10

Remounting . . .7E-10

SPECIAL TOOLS ,7E-10

DESCRIPTION

CAUTION:

o Once wheel (tire) on one side got stuck

in mud, sand, etc. and started slipping,

do not drive wheels at high speed. lt

would allow stucked wheel to go down

deeper and cause excessive wear to clutch

of LSD.

o Be sure to use only specified gear oil for

LSD.

o Change LSD oil at specified interval.

WARNlNG:

Do not drive wheel(s) (tire) when wheel on

one side is jacked up (i.e., jacked wheel off

i ttre ground but wheel on the other side on

I ,n" ground). Vehicle may start in motion.

r:- 7E.2 DIFFERENTIAL

-)-.-c ^

lzP ^'r\

1 K:YL/

' l|Wrt'\-

?v\9&,

^.\i-l

\.,f /

26 25

,\ )^

(M*:'

T'V?o,'

), ),

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21 .

22.

24.

25.

26.

27.

28.

29.

Differential left case

Diff erential right case

Screw

Outer plate (f riction platel

lnner plate (f riction disk)

Pressure ring

Side gear

Pinion shaft

Pinion

lnner shim (spring disk)

Outer shim (spring Plate)

Universal ioint f lange

Bevel pinion gear set

Bevel pinion sPacer

Shim(s)

Rear bearing

Front bearing

Oil seal

Washer

Nut

Differential carrier ass'Y

Bolt

Nut

Lock washer

Bolt

Lock plate

Bearing adiuster

Differential side bearing

LSD case assemblY

* : Refer to FOREWORD.

2b1s 12

Fis. 7E-1 LSD

DIFFERENTIAL 7E-3

ON VEHICLE SERVICE

MAINTENANCE SERVICE

When checking level of LSD oil or changing it,

use the same manner as conventional type dif-

ferential except specif ic type of oil as given below.

For check interval and practical procedures,

rcfcr tO SECTION OB Of "VITARA SERVICE

MANUAL".

NOTE:

o lt is absolutely necessary to use LSD gear oil

for LSD.

o Use of 80W-90 LSD gear oil is recommended

when it is anticipated that ambient tempera-

ture goes down below 0"C (32"F) depending

on area or season.

UNIT REPAIR OVERHAUL

LIMITED SLIP DIFFEREN.

TIAL (LSD, REAR}

DISMOUNTING

Refer to item ,,DISMOUNTING of REAR DIF-

FERENTIAL" in SECTION 7E of "VITARA

SERVICE MANUAL". (The same dismounting

procedure is applicable as conventional type

rear differential.)

DISASSEMBLING

REfCr tO itEM ,,DISASSEMBLY Of REAR DIF.

FERENTIAL" in SECTION 7E of "VITARA

SE RVICE N4ANUAL". (The same disassembling

c.oceCure is applicable as conventional type rear

: -:.ential except LSD case assembly.)

INSPECTING OF LSD CASE

ASSEMBLY

1. Using special tool, check differential torque

(rotating torque) of LSD.

DIFFERENTIAL

TOROUE (Rotating 2.4-7.2ks-m

torque) SPECI F ICA- (17 .4 - 52.0 lb-ft)

TI ON

1. Special tool

(Differential tdrque checking tool 09928-06010)

2. LSD case assembly

3. Vise

4. Torque wrench

F ig. 7E-2

When measured value is not within above spe-

cif ication, disassemble LSD case assembly and

repair or replace any defective part.

Oil specification

Oil capacity

7E-4 DIFFERENTIAL

DISASSEMBLING OF LSD CASE ASSEMBLY

* : Refer to FOREWORD. 1. Differential left case

2. Differential right case

3. Screw

4. Outer plate (friction Plate)

5. lnner plate (friction disk)

6. Pressure ring

7. Side gear

8. Pinion shaft

9. Pinion

10. lnner shim (sPring disk)

1 1 . Outer shim (sPring Plate)

Fig. 7E-3 LSD Case AssemblY

DIFFERENTIAL 7E-5

1 . Check that match mark is stamped on each

differential case (right and left). lf not, put

such marks. (Refer to Fig. 7E-4.\

2. Loosen differential case screws by turns

evenly and a little at a time.

NOTE:

When it is hard to loosen screws, try loosening

thern while aoplying pressure (no more than

400 kg, 882 lb) to cases by using special tool

and hydraulic press.

Note that applied pressure should never exceed

400 kg (882 lb).

Press

Special tool

(Oil seal remover &

installer No.2

09951-1 821 0)

LSD case assembly

Special tool

(Bearing installer

support

09944-7821 0)

Fig. 7E-5

3. Separate differential cases (right and left).

Take out all parts from each case. Place all

parts in such order as they are removed and

in two separate groups, right side parts and

left side ones. (Refer to Fig. 7E-3.)

INSPECTING OF LSD CASE

COMPONENT PARTS

NOTE:

Vl/ash disassembled parts thoroughly and dry

them with compressed air before inspection.

Side Gear and Pinion

o Check each gear tooth for wear, damage and

breakage.

o Check spline of side gear for wear and damage.

1. Side gear

2. Pinion gear

F ig. 7E-6

a [:)o

Differs--; o"^

l\4atc^ -:'<

Fis.7E-4

7E.6 DIFFERENTIAL

Plates, Shims and Pressure Rings

o Each plate and shim has either 4 (outside) or

6 (inside) lugs. Check them for crack, nick

and any other damage' lf nick is found, correct

it with oil stone. Replace part with uncorrect-

able nick or any other defect with new one'

o Check rubbing or sliding surface of each plate

and shim for excessive wear and faulty condi-

tion caused by heat such as discoloration.

lf discoloration or excessive wear is noted,

replace with new Part.

o Check sliding surface of pressure ring against

outer plate for nick and damage. Try to correct

defective part by using oilstone and compound

on surface plate. lf uncorrectable, replace

with new part.

NOTE:

There may be a sign as if something had struck

hard on inside of rubbing or sliding surface of

each plate, shim and pressure ring' As it is

caused by spring force of shims, do not take it

as abnormal wear.

Check point

Outer plate

lnner plate

Pressure ring

lnner shim

( | f equ ipped )

Outer shim

o On each plate and shim, measure thickness at

sliding surface ("a" in figure below) and at

lug l"b" in figure below) to obtain their

difference, Take several measurement at dif-

ferent places. When difference ("b" - "a"\

exceeds below, replace with new part.

Wear limit of plate 0.1 mm (0.004 in.)

and shim (b - a)

'::- cPed)

F ig. 7E-8

o Check each plate (both inner and outer) for

distortion (flatness) by taking measurement

while turning plate on surface plate as shown

below. When pointer def lection exceeds below

limit, replace with new Plate,

Distortion (deflec- 0.08 mm (0.003 in.)

tion) limit of plate

Fig.7E-9

Fis. 7E-7

DIFFERENTIAL 7E.7

Differential Case lnner Parts

Check following parts for burr and nick. Correct

them with oil stone, if any.

(a) Differential case contact surface with outer

shim

(b) Grooves in inside of differential right case

and differential right case (inside)

(d) lnner surface of pressure ring and spherical

surface of differential pinion

(e) V-shaped groove of pressure ring and V-

shaped part of pinion shaft

(f) SlidinS surfaces of side gear (outside) and

pressure ring

(g) Grooves in side gear (outside)

(h) Sliding surfaces of pinion shaft and differen-

tial pinion

(i) Projecting part of pressure ring (outsice,

REASSEMBLING OF LSD CASE

ASSEMBLY

1. Before installing parts in differential case,

measure them and check clearance between

outer shim and differential case as described

below and then adjust it as necessary.

1) Take measurements "A", "B" and "C" of

differential case (right and left) and obtain

dimension "D" by using equation given

below.

'D" =" A" + "8" - "C"

, -.1,,

Fis.7E-10 F is. 7E-7 1

7E.8 DIFFERENTIAL

2) Put inner and outer shims (one each on the

same side) or outer shims together as shown

below and measure thickness "E" of each

set (right and left) by using micrometer.

Then comparing thickness of both sets,

meke their difference as small as possible

by selecting shims.

NOTE:

One new shim (whether outer or inner) is 1.7 mm

(0,067 in.) thick. Use this data as referencewhen

using new one.

3) Put inner and outer plates (one each on the

same side) together as shown below and

measure thickness of each set (right and

left) by using micrometer.

Then comparing thickness of both sets,

select inner and outer plates combination

so that their thickness difference is within

fol lowing specification.

NOTE:

o There are two types of plate (whether inner

or outer); one is 1.7 mm (0.067 in.) thick and

the other 1.8 mm (0.071 in.). Use these data

as reference when using new plate.

o There is no difference between both sides of

each plate.

Thickness difference STD

between right and I O - 0.05 mm

left sets I tO - 0.002 in.)

Fis.7E-13

4) lnstall pressure rings, differential pinion

shaft, pinions, side gears and plates as shown

below and measure width "F". Then add

"F" and "E" (thickness of inner and outer

shims together) on both sides. Sum is dimen-

sion "G".

NOTE:

r When taking measurement "F", make sure

that V-shaped groove in pressure ring is in

close contact with pinion shaft.

o For accurate measurement, check to make

sure no oil is on each part.

ffi

1 . Outer plates

2. I nner plates

3. Thickness

ffi

,fl 1.

2. Outer shim

lnner sh im

F is. 7E-12

"G" ="F" + "E" +"E" 1. V-shaped

2. Pinlon shaft -

121

Fig. 7E-14

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