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)
:
L_
I
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
t'
i
-)-.-c ^
lzP ^'r\
1 K:YL/
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26 25
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,\ )^
16
(M*:'
T'V?o,'
), ),
1.
,
J.
4.
5.
6.
7.
o.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21 .
22.
aa
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
q
22
* : 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
J3
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)
5
11
/1
Fig. 7E-3 LSD Case AssemblY
t

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).
1.
2.
J.
4.
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
1,
2.
?
4.
5.
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
(c) Contact surfaces of pressure ring (outside)
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"
a
, -.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.
1
ffi
r1
*1
1 . Outer plates
2. I nner plates
3. Thickness
1
tu
ffi
r
T
2
2
,fl 1.
2. Outer shim
lnner sh im
fl
F is. 7E-12
\
.I
\
.I
"G" ="F" + "E" +"E" 1. V-shaped
2. Pinlon shaft -
121
Fig. 7E-14

DIFFERENTIAL 7E.9
Clearance between
shim and case 0'06 - o'20 mm
(D _ G) (0.0023 - 0.0078 in.)
Next, subtract above "G" from "D"obtain-
ed in step 1). Difference is clearance be-
tween differential case and shim. lf it is not
within below specification, change inner
and outer plates so that specified value is
atta i ned.
Left case 4. Match mark
Right case 5. Groove of right case
Outer shim 6. Lug of shim
Fis. 7E-16
5. Tighten LSD case screws in diagonal order
evenly a little at a time.
NOTE:
lf cases do not fit tightly even after screws were
tightened, it is because lugs of shim is not in
grooves of case properly. (Shim is caught between
cases.) ln such case, reinstall shim and cases.
Fig.7E-17
ti 2. Apply specified gear oil to each part before
installation, particularly in ample amount to
contact surface and sliding surface.
3. lnstall outer piates and inner plates making
sure that they are in proper order and then
inner and outer shims using care for their
installing direction.
4. Put differential cases (right and left) together
by aligning their match marks,
Before tightening screws, check that shim is
properly positioned so that its lugs would fit
in grooves in right case when screws are
tightened.
1. Outer shim
2. lnner shim 3. Outer plate _
4. I nner plate
Fig.7E'15

7E.10 DIFFERENTIAL
6. After installation, measure differential torque
(rotating torque) with special tool so as to
check friction force of plates (clutch).
NOTE:
For accurate value, turn gear to run it in before
taking measurement.
ADJUSTMENT AND REASSEMBLY
For inspection, adjustment and reassembly of
drive bevel gear, drive bevel pinion and differ-
ential carrier, reter to SECTION 7E of "VITARA
SERVICE MANUAL". (The same adjustment
and reassembly procedures are applicable as
conventional type rear differential.)
REMOUNTING
For installation of LSD to rear axle housing
(differential housing), refer to SECTION 7E of
"VITARA SERVICE MANUAL". (The same
remounting procedure is applicable as conven-
tional type rear differential.)
SPECIAL TOOLS
\
DI FFERENTIAL TOROUE SPECI F ICATION
When new plates
insta lled 4.8 - 7.2 ks-m
(34.7 - 52.0 rb-ft)
When used plates
installed 2.4 - 7.2 ks-m
(17.4 - 52.0 lb-ft)
1. Special tool
( Differential torque checking tool)
2. LSD case assembly
3- Vise
4. Torque wrench
Fis. 7E-18
,&ffi
0995 1-1 82 1 0
Oil seal remover &
installer No. 209944-78210
Bearing instal ler support
09928-0601 0
Differential torque
checking tool

SUZUKI MOTOR CORPORATIOil