there is a tsb for this...
http://www.suzuki-forums.com/attach...-1999-2005-vitara-grand-vitara/8986d1265146887-cv-joint-free-play-shaft-buliten

VITARA

Section Title: Driveline/Axle
TSB No. TS 06 05227

Division: Automotive
Category: Technical

SUBJECT:
FRONT DIFFERENTIAL OIL SEAL REPLACEMENT

MODEL(S):
VITARA (5Q420 & 5Q625L), GRAND VITARA (5Q625W), GRAND VITARA XL-7 2001~2003 ONLY (JA627)

YEAR:
1999-2005

CONDITION:
There is now a countermeasure part available to address premature seal failure on the front differential at the right axle.

CAUSE:
Axle shaft movement.

CORRECTION:
When replacing the right side front differential oil seal be sure to install the new additional support ring behind the oil seal. See below for parts information and instructions.

 

Here is some posted info on the subject too.

http://www.suzuki-forums.com/1g-1999-2005-vitara-grand-vitara/29722-cv-joint-free-play.html

 

This update works wonders too! Never have a seal leak there again after doing this update!

 

Another one to confirm that this works - I fitted this about 30000km ago, after major play developled, replaced the oil seal twice thinking I'd damaged it the first time installing it - since installing the support bush, hasn't leaked a drop. (Although i do run manual hubs and don't leave them engaged all the time) Almost 0 play in the CV too

 

I was just wondering...do you replace the stock oil seal with the new supportive one or do you simply add the white one?

Also, is it a difficult job to do? How much time for it if you are a medium beginner DIY?

Thanks,
Doom

 

you add the white piece inside and use a stock seal over it.
a beginner should be able to do this in 3-4 hrs..
i dont recommend taking apart the knuckles, i leave those alone and just pull out the front diff..

 

Ok, if I understand well, I just remove the whell, brake, hub and everything until I get to remove the knuckle shaft, I drain the diff, remove the seal, put the white one behind, put back the seal and mount everything back?

 

thats the hard way of getting at it, you will need to unhook the knuckle from the lower control arm.
be careful, the spring sit on the control arm and is under tensio..

 

Sorry to dig up an old post but I have a question regarding this fix. Is there any reason this fix would not work on a '02 Chev Tracker?

I ask because while I can find the part at suzuki, Chevy has no part number or TSB or ANYTHING listed like this and was wondering if there was some change in the diff that prevents this from working.

 

I can't believe that piece of plastic is so expensive D:

 

How expensive is "so expensive"?

 

It should fit and function on the Tracker as it does on the (same) Zuki diff.

 

well the drive shaft support (SV-27619-65D00) on my local Suzuki Agency cost $90, and in Ebay is similar, so I say that for a tiny piece of plastic, is too much money

 

Ever heard of supply & demand? I have the piece of plastic and if you want it, you'll pay me the price I want for it.

Let's take a different approach - I'll give you the dimensions (I think I have them in a file somewhere) and you can find a machinist in Costa Rica and have them turn one up for you - you'll probably find that the cost of a machinist's time for low volume production to be quite high.

Or maybe you can search a little harder ...

https://www.ebay.co.uk/itm/Suzuki-V...rt-Bearing-Genuine-Oil-Seal/132394073501?hash=item1ed34d3d9d:g:72UAAOSwK~RaBbA2

Just so it's clear - I'm not in the business of supplying these bushings - I bought mine from Bits4vits and I certainly didn't pay anywhere near USD$90

 

Yeah you are right lol

And if you have the dimensions that would be great! It's a long shot but maybe it can be done here at a cheap price (labor here is cheap in some places)

And actually I saw that one, but they do not ship to Costa Rica, so I would have to send it first to US, then have a freight forwarder send it here, and that will save me $20, which is not bad.

I'll think it, because the oil leak I have is not that bad. When I change my motor oil, I always inspect all the car, and the oil level on the front diff never goes down the mark.

 

And actually I saw that one, but they do not ship to Costa Rica, so I would have to send it first to US, then have a freight forwarder send it here, and that will save me $20, which is not bad.

That's sort of how I got mine - ship it to the US, where my daughter was studying and then pick it up whilst visiting her.