[russgt]

Hi guys,

I bought my niece a 98 Grand virtara with a j20a. Its a great car. Or so i thought. It has a really bad grinding/ banging noise coming from under it when in 4wd.

I have taken the FWH off and put standard locked hubs on to check it it was that but it is still there.

Please look at the video below and let me know what you think it is.

My thinking is its something in the front diff?

https://www.youtube.com/watch?v=pUhXfzZ ... zscQ9stQAA



[youtube]pUhXfzZtpbI&list=UUx-tY9LbHO40vzscQ9stQAA[/youtube]

Hmm i cant embed the video sorry

[Gwagensteve]

That's the front diff actuator issue. It's very common. If you have freewheeling hubs, I think it's possible to eliminate it altogether, but I'm far from a GV expert. Best to do a search, the noise and it's repair has been covered before.

[russgt]

Ok thanks! They have a little pump which pressurizes / vacuums them into 4wd right? And the pump could have leaks causing only half engagement? Is that the basic gist of it?

Do i need to take the diff out to fix the actuator?

[Gwagensteve]

From memory, that's it.

Don't believe the diff has to come out. Could be wrong

[russgt]

This post mentions what i think it feels and sounds like. Hopefully not as that sounds like bearings etc...

GM Tech Service Bulletin, Bulletin No.: 01-04-19-003, Date: April, 2001
Subject:
Harsh Clunk Noise From Front Axle While in 4WD and During Turning Maneuvers (Replace Front Differential Case, Actuator and Side Bearings)
Models:
1999 Chevrolet Tracker with Four-Wheel Drive
Condition
Some customers may comment on a harsh clunk or popping noise coming from the front axle. This condition is most apparent while driving in 4WD at low speeds on loose traction surfaces such as gravel or snow and turning right or left.
Cause
Inside the front differential case, the teeth of the free wheel axle hub may jump a tooth resulting in the noise.
Correction
A modification was made to the design of the front differential case, which should reduce the likelihood of the free wheel hub teeth from jumping.
Replace the front axle differential case, actuator and side bearings using the service procedure and part numbers as shown.
Important: With the new design differential case, the teeth may still jump under extreme torque load conditions, such as making tight turn maneuvers in 4WD on hard dry surfaces resulting in a similar noise. This noise is now considered to be a normal vehicle operating characteristic. Driving on high traction surfaces in 4WD is not necessary and contributes to excessive torque load on the front axle. Customers should be advised to shift into 2WD when driving on such surfaces.

http://www.suzuki-forums.com/1g-1999-20 ... post130766

[klutched]

Just the casual 2 step

Nah mine does it sometimes, not bad like that though. Only when turning on angles any shiz.

Go to 1:28 and you can hear it click.
https://www.youtube.com/watch?v=oFvpC3s ... J6LsT2tMiQ

[russgt]

Do you know what would be causing this then Klutched? Pump or actual front diff is rooted?

[klutched]

NFI, I have a front air locker so all the pump and shit is long gone! Could just be my CVs clicking.

[ninjamoses]

I wouldn't have thought it would be the pump itself mate.

I'd guess either the actuator in the front diff is skipping/rooted as per the tech bulletin you posted above, or it could also be the transfer case front output skipping. That plagued the early year V6 models, not sure if J20A ones were also affected?? Certainly sounds the same anyway. Either way, easiest/cheapest fix is probably going to be a complete replacement of either the diff or transfer once you figure out which one it is.

Fingers crossed its the diff for your sake, much easier to source and swap than the transfer!

[russgt]

Crap.

How would 5.12's go with the J20A?

[ninjamoses]

I presume its auto looking at that vid, so would be 4.88 ratios standard I believe?

5.12s would work well. Would let her go up a size or two in tyres and still have good gearing.

[russgt]

Na its manual.

She has larger tyres on now at 225,70,16.

[atari4x4]

russgt wrote:

Crap.

How would 5.12's go with the J20A?

rad to the power of sick.

[russgt]

Guys check out this video I took.

I checked the pressure from the little pump. It's about 5.8psi. I pressured it in the video with an external pump to 7psi. So it's not that. It's still doing it.

This is from the transfer case to the front diff. To me it looks like the jump starts at the diff and bounces through the shaft. So I'm hoping it's the diff. What do you guys think?

http://youtu.be/dsYTuF8bbTg

[henno]

5psi should be enough (I think the suzuki spec was 5-8psi or some such). It'll be the actuator inside the diff, I reckon. I say get free wheeling hubs and swap out the entire lot for vit gear instead. Otherwise you can follow the numerous threads on how to cure it, although it can be a bit of a prick of a job from all reports.

[zoukshin]

did you measure the pressure at the pump or the diff ? You may have a leak somewhere in the line.
But from the sound of it, your diff might be the problem. Time to install a locker, some would say

[nobes]

i thought of this straight away. http://www.auszookers.com/forum/viewtop ... r+slipping

But yours doesn't seem to slip back to 4wd Low

[russgt]

I measured the pressure coming straight out of the pump. Ie no hoses. 5.8psi.

And at the diff with the hoses. Same.

I also pressured up the diff with a hand pump and it held pressure pretty well for a few seconds. I should have leak checked it for longer.

I can get some 5.12 diff gears for rear and a whole new front diff from an xl7 installed by ninja Moses on here. Champion! Do you guys think that would be good?

It's only an Ali diff again though. Should be good for her though. She isn't a hard core 4wder.

[klutched]

Hmm to me it sounds like the transfer, when it clicks it moves the gearbox and motor around a bit. Then again the diff has a sudden movement when it clicks.

[nobes]

The tailshaft literally stops moving when you get the knock also, but i guess that could still mean either transfer or diff.
I'm getting a clunk also but im' hoping mine will just be CV's worn out.

[russgt]

Yeah i am trying to figure out if its diff or transfer. To me though on that last bang, it looks like the front diff moves then the shaft slows. So to me it looks like its the front diff.

[russgt]

nobes wrote:

i thought of this straight away. viewtopic.php?f=5&t=47749&hilit=transfer+slipping

But yours doesn't seem to slip back to 4wd Low

These threads have some absolute gold in them! Thanks mate

[atari4x4]

Have a look at stekky's first posts, (steak_knife) he was all cute n newb back then.

I miss steaky!

[russgt]

Yes i saw that. However my issue is when im in 4LO. I havent noticed the actual gear shifter moving at all. Just a grinding etc when in gear. I havent tested it in 4HI either. Damn i should have...

Ill test it in 4HI on thursday.

[russgt]

So Kris replaced the front and rear diffs with late model gv 5.12 diffs.

We worked out a way of using late model diffs on a j20a motor without bashing the sump like some people do. You just drill out the two already piloted holes in the front diff 3rd member mount with a 11mm drill and use the old 3rd member instead of the new one. Bolts up perfectly.

However the problem still exists... Friking hell!!!

So now trying to find out if the j20a grand vitara transfer case is the same as a v6 grand vitara transfer case. Please help if you know!

[Zook_Fan]

Take a photo of your gearbox and transfer as installed in the car. My guess would be the J20a transfer is the same as the G16a/b/H20a transfer rather than the H25a. Just speculation though.

[atari4x4]

^^^ that is my understanding.