Drive Axle - Front Differential Right Side Seal Leaks
TSB No. TS 07-0110230Section Title: Differential
Division: Automotive
Category: Technical
SUBJECT:
Oil leakage from the Front Differential Right Side Seal
MODEL:
Vitara, Grand Vitara (5Q416/420/625)
YEAR:
1999-2001
CONDITION:
A condition may exist on 5Q416/420/625 Models where the front differential housing may leak fluid from the right side oil seal, after the differential oil is replaced or the front differential receives repair service.
CAUSE:
Insufficient oil flow through the free axle case holes during 2WD operation.
CORRECTION:
In the event an affected vehicle requires that front differential oil be added or refilled, follow the updated fill procedure as prescribed in this bulletin.
PARTS IDENTIFICATION:
For all vehicles equipped with the front differential housing shown in Fig. 1, follow the appropriate refill procedure outlined in this bulletin. For vehicles with the housing shown in Fig. 2, refer to the refill procedure in the Service Manual.
REFILL PROCEDURES
In cases where the front differential has been disassembled/assembled or replaced, and requires the axle shafts be removed:
1. Prior to installing the front differential assembly into the housing, apply Suzuki Super Grease onto the grooved areas of the carrier which hold the axle shafts, for lubrication.
2. Before attaching the right axle to the differential, ensure that both the fill plug and drain plug are secure in the housing, then pour 1.0 liter (2.1 pint, 34 oz.) differential oil, through the right side hole of the differential housing. Use care to measure the proper amount of fluid used in the front differential to avoid insufficient lubrication.
3. Road test the vehicle, in 4WD, for a minimum of 2 km (1.2 miles) for the initial lubrication of the components.
In cases where only the front differential oil is replaced (axle shafts not removed):
1. Alter draining the front differential housing, install the drain plug into the lower (drain) hole.
2. Lower the vehicle to the ground. Reposition the arms of the hoist in order to lift the front of the vehicle only, or use an appropriate lifting device. Lift the front of the vehicle until the bottom of the front bumper is raised to the prescribed distance off the floor. Refer to the chart in Fig. 3 for the prescribed height.
3. Using the fill hole, pour 1 liter (2.1 Pt., 34 oz.) differential oil into the housing. Use care to measure the proper amount of fluid used in the front differential to avoid insufficient lubrication. Install the fill plug into the front differential housing prior to lowering the front of the vehicle to the floor.
4. Road test the vehicle, in 4WD, for a minimum of 2 km (1.2 miles) for the initial lubrication of the components.