Suzuki VITARA 1993 - Service Manual

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Summary

Section 7 E: Differential (LSD, Rear)

General Description

Explains the function of the Limited Slip Differential (LSD) and its components.

On-Vehicle Service

Details maintenance service procedures for the LSD, including oil specifications.

Unit Repair Overhaul

Introduces the unit repair and overhaul procedures for the rear LSD.

Limited Slip Differential (LSD) Dismounting & Disassembling

Covers dismounting and disassembling the LSD unit.

Maintenance Service Details

Provides details on LSD oil specification and capacity for maintenance.

Dismounting Procedure

Refers to the main manual for the procedure of dismounting the rear differential.

Disassembling Procedure

Refers to the main manual for disassembling the rear differential, noting LSD case assembly is different.

Inspecting LSD Case Assembly

Describes how to check the differential torque of the LSD case assembly using special tools.

Disassembling LSD Case Assembly

Provides figures and part lists for the disassembly of the LSD case assembly.

Inspecting LSD Case Component Parts

Details inspection points for side gear and pinion teeth for wear, damage, and breakage.

Plates, Shims, and Pressure Rings Inspection

Explains how to measure plate and shim thickness for wear limits.

Plate Distortion Check

Describes checking plates for distortion (flatness) and their deflection limits.

Differential Case Inner Parts Inspection

Lists inspection points for burrs and nicks on differential case inner parts.

Reassembling LSD Case Assembly

Starts the reassembly procedure with measurement steps for differential case and shims.

Shim Thickness Measurement and Selection

Details measuring and selecting shims for proper thickness.

Plate Thickness Measurement and Combination

Explains measuring and combining inner and outer plates for thickness.

Final Assembly Measurements and Calculations

Describes measuring and calculating dimensions for the final assembly.

Clearance Between Shim and Case

Details calculating and checking the clearance between shim and case.

Installation of Plates and Shims

Describes the proper installation of outer plates, inner plates, and shims.

Tightening LSD Case Screws

Provides instructions for tightening LSD case screws in a specific order.

Differential Torque Specification

Specifies torque values for new and used plates during differential reassembly.

Adjustment and Reassembly

Refers to the main manual for adjustment and reassembly of related components.

Remounting

Refers to the main manual for installation of LSD to the rear axle housing.

Special Tools

Lists and illustrates special tools required for LSD service.

Summary

Section 7 E: Differential (LSD, Rear)

General Description

Explains the function of the Limited Slip Differential (LSD) and its components.

On-Vehicle Service

Details maintenance service procedures for the LSD, including oil specifications.

Unit Repair Overhaul

Introduces the unit repair and overhaul procedures for the rear LSD.

Limited Slip Differential (LSD) Dismounting & Disassembling

Covers dismounting and disassembling the LSD unit.

Maintenance Service Details

Provides details on LSD oil specification and capacity for maintenance.

Dismounting Procedure

Refers to the main manual for the procedure of dismounting the rear differential.

Disassembling Procedure

Refers to the main manual for disassembling the rear differential, noting LSD case assembly is different.

Inspecting LSD Case Assembly

Describes how to check the differential torque of the LSD case assembly using special tools.

Disassembling LSD Case Assembly

Provides figures and part lists for the disassembly of the LSD case assembly.

Inspecting LSD Case Component Parts

Details inspection points for side gear and pinion teeth for wear, damage, and breakage.

Plates, Shims, and Pressure Rings Inspection

Explains how to measure plate and shim thickness for wear limits.

Plate Distortion Check

Describes checking plates for distortion (flatness) and their deflection limits.

Differential Case Inner Parts Inspection

Lists inspection points for burrs and nicks on differential case inner parts.

Reassembling LSD Case Assembly

Starts the reassembly procedure with measurement steps for differential case and shims.

Shim Thickness Measurement and Selection

Details measuring and selecting shims for proper thickness.

Plate Thickness Measurement and Combination

Explains measuring and combining inner and outer plates for thickness.

Final Assembly Measurements and Calculations

Describes measuring and calculating dimensions for the final assembly.

Clearance Between Shim and Case

Details calculating and checking the clearance between shim and case.

Installation of Plates and Shims

Describes the proper installation of outer plates, inner plates, and shims.

Tightening LSD Case Screws

Provides instructions for tightening LSD case screws in a specific order.

Differential Torque Specification

Specifies torque values for new and used plates during differential reassembly.

Adjustment and Reassembly

Refers to the main manual for adjustment and reassembly of related components.

Remounting

Refers to the main manual for installation of LSD to the rear axle housing.

Special Tools

Lists and illustrates special tools required for LSD service.

This document is a Supplementary Service Manual for the Suzuki Vitara, specifically addressing the Limited Slip Differential (LSD). It is intended to be used in conjunction with the main Vitara Service Manual (99500-60A10). The manual provides detailed information for servicing the LSD, including general description, maintenance, disassembly, inspection, and reassembly procedures.

Function Description:

The LSD, as its name indicates, incorporates a limited slip device. Beyond the function of an ordinary differential, which allows the right and left wheels to rotate at different speeds during turns, the LSD has an additional function: it prevents wheel slip when one wheel starts losing traction. This mechanism helps maintain traction and stability, particularly in challenging driving conditions.

Important Technical Specifications:

Differential Torque (Rotating Torque) Specification:
- When new plates are installed: 4.8 – 7.2 kg-m (34.7 – 52.0 lb-ft)
- When used plates are installed: 2.4 – 7.2 kg-m (17.4 – 52.0 lb-ft)
Wear Limit of Plate and Shim (b - a): 0.1 mm (0.004 in.)
Distortion (Deflection) Limit of Plate: 0.08 mm (0.003 in.)
Thickness Difference between Right and Left Shim Sets (STD): 0 – 0.05 mm (0 – 0.002 in.)
Clearance between Shim and Case (D - G): 0.06 – 0.20 mm (0.0023 – 0.0078 in.)
LSD Gear Oil Specification: API GL-5 SAE 90 or 80W-90
Rear LSD Oil Capacity: 2.2 liters (4.6/3.9 US/Imp. pt.)

Usage Features:

The LSD enhances vehicle performance by preventing excessive wheel spin on one side, which can occur when one wheel loses traction (e.g., in mud, sand, or slippery conditions). This allows power to be transferred to the wheel with better grip, improving overall traction and vehicle mobility.

Warnings and Cautions:

Do not drive with one wheel jacked up: Driving the wheels when one side is jacked up (wheel off the ground, other on the ground) can cause the vehicle to start moving.
Avoid high-speed driving with a stuck wheel: If a wheel gets stuck and starts slipping, do not drive at high speeds. This can cause the stuck wheel to sink deeper and lead to excessive wear on the LSD clutch.
Use only specified gear oil: It is absolutely necessary to use LSD gear oil for the LSD unit.
Recommended oil for cold climates: Use 80W-90 LSD gear oil if ambient temperatures are expected to drop below 0°C (32°F).

Maintenance Features:

Oil Check and Change: The procedure for checking and changing LSD oil is similar to a conventional differential, but a specific type of oil must be used. Refer to Section 0B of the main "VITARA SERVICE MANUAL" for check intervals and practical procedures.
Regular Oil Change: Change LSD oil at specified intervals.
Component Inspection:
- LSD Case Assembly: Check differential torque (rotating torque) using a special tool (09928-06010). If the measured value is outside specifications, disassemble and repair/replace defective parts.
- Side Gear and Pinion: Inspect gear teeth and spline for wear, damage, or breakage.
- Plates, Shims, and Pressure Rings:
  - Check for cracks, nicks, or other damage. Correct nicks with an oil stone or replace the part if uncorrectable.
  - Inspect rubbing/sliding surfaces for excessive wear or discoloration due to heat. Replace if noted.
  - Check the sliding surface of the pressure ring for nicks and damage. Correct with an oil stone and compound, or replace if uncorrectable.
  - Measure the thickness difference between the sliding surface and the lug (b-a). Replace if it exceeds the wear limit.
  - Check plates for distortion (flatness) using a surface plate. Replace if pointer deflection exceeds the limit.
- Differential Case Inner Parts: Check for burrs and nicks on contact surfaces, grooves, and V-shaped parts. Correct with an oil stone if necessary.
Disassembly and Reassembly:
- Dismounting and Disassembling: Follow procedures outlined in "DISMOUNTING of REAR DIFFERENTIAL" and "DISASSEMBLY of REAR DIFFERENTIAL" in Section 7E of the main "VITARA SERVICE MANUAL."
- LSD Case Assembly:
  - Before installing parts, measure the differential case dimensions ("A", "B", "C") and calculate "D" ("D" = "A" + "B" - "C").
  - Measure the thickness "E" of inner and outer shim sets and select shims to minimize the difference between right and left sets.
  - Measure the width "F" after installing pressure rings, differential pinion shaft, pinions, side gears, and plates. Calculate "G" ("G" = "F" + "E" + "E").
  - Calculate the clearance between the shim and case (D-G). Adjust by changing inner and outer plates if not within specification.
  - Apply specified gear oil to all contact and sliding surfaces before installation.
  - Install outer and inner plates and shims carefully, ensuring correct order and direction.
  - Align match marks on differential cases (right and left) and ensure shim lugs fit properly into grooves before tightening screws.
  - Tighten LSD case screws diagonally and evenly.
  - After installation, measure differential torque (rotating torque) again to check the friction force of the plates (clutch). Turn the gear to run it in before taking the measurement for an accurate value.
Adjustment and Remounting: For inspection, adjustment, and reassembly of the drive bevel gear, drive bevel pinion, and differential carrier, refer to Section 7E of the main "VITARA SERVICE MANUAL." The remounting procedure for LSD to the rear axle housing is also covered in Section 7E of the main manual.

Special Tools:

Differential Torque Checking Tool: 09928-06010
Oil Seal Remover & Installer No. 2: 09951-18210
Bearing Installer Support: 09944-78210

This supplementary manual ensures that technicians have the specific information needed to properly service the LSD component, maintaining its functionality and extending its lifespan.