Suzuki Vitara, Grand Vitara, XL7 2000-06

Pinion Seal

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Removal & Installation



Except Grand Vitara-2006
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The brake calipers and pads or brake drum must be removed so that there is no additional drag when measuring pinion bearing preload.



    Driveshaft
     
    Wheels
     
    Brake calipers and pads or brake drum
     

  4.  
  5. Use an inch lb. torque wrench and measure and record the amount of torque required to maintain pinion rotation through several revolutions.
  6.  
  7. Remove or disconnect the following:

    Pinion flange
     
    Pinion seal
     
    Pinion bearing
     
    Collapsible spacer
     

  8.  

To install:


NOTE
Use a new collapsible spacer and flange nut for assembly.

  1. Install or connect the following:

    Collapsible spacer
     
    Pinion bearing
     
    Pinion seal
     
    Pinion flange
     

  2.  
  3. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly.
  4.  
  5. Take frequent bearing preload torque readings. Tighten the flange nut to achieve the preload torque readings originally recorded.
    CAUTION
    Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut.

  6.  
  7. Install or connect the following:

    Driveshaft
     
    Brake calipers and pads or brake drum
     
    Wheels
     

  8.  
  9. Fill the differential with gear lubricant and check for leaks.
  10.  

Grand Vitara-2006
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise vehicle, remove wheels and brake pads and calipers.
  4.  
  5. Mark propeller shaft and pinion flange for installation.
  6.  
  7. Remove rear propeller shaft.
  8.  
  9. Drain rear axle, or install catch pan under work area.
  10.  
  11. Remove pinion nut and record bearing preload.
    NOTE
    The brake calipers and pads or brake drum must be removed so that there is no additional drag when measuring pinion bearing preload.

  12.  
  13. Make mating marks on drive bevel pinion and companion flange.
  14.  
  15. Remove flange from drive bevel pinion. Use puller tool if it is hard to remove.
  16.  
  17. Remove pinion seal with seal removing tool.
  18.  
  19. Remove pinion bearing.
  20.  
  21. Remove collapsible spacer.
  22.  

To install:

  1. Install new Collapsible spacer.
  2.  
  3. Install pinion bearing.
  4.  
  5. Lube pinion seal lip and carefully install.
  6.  
  7. Install pinion flange align marks.
  8.  
  9. Check pinion flange nut and install Thread locking liquid.
  10.  
  11. Tighten pinion flange nut gradually then set to recorded preload. Standard preload is 8-15 inch. lbs. (0.9-1.7 Nm).
  12.  
  13. Install front propeller shaft align mating marks.
  14.  
  15. Tighten rear propeller shaft mounting bolts tighten to 62 ft. lbs. (85 Nm).
  16.  
  17. Refill rear differential with specified oil.
  18.  
  19. Install wheels, brake pads and calipers.
  20.  
  21. Check pinion seal for leaks.
  22.  

 
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