Component Disassembly & Reassembly: Differential: Reassembly

1. Assemble differential case. Install side gear washers on differential gears. Install side pinion washers to differential pinions. Install side pinion shaft. Align lock pin holes with differential case.
2. Measure left-side differential gear thrust play by using 2 screwdrivers to move gear up and down. Read movement of dial indicator. Measure right-side differential gear thrust play by moving gear up and down by hand. Thrust play should be .002-.013" (.05-.33 mm). Select thrust washers to obtain correct thrust play. Thrust washer thicknesses are available from .035" (.89 mm) to .047" (1.19 mm) in .002" (.05 mm) increments. Install thrust washers and side gears in case. If possible, install same size thrust washers on both sides. Recheck thrust play.
3. Drive in spring pin from right side until flush with differential case surface. Press in differential left-side bearing.
4. Install speedometer drive gear. Support differential so left-side bearing is floating. Press in differential right-side bearing using bearing installer and copper hammer.
5. Hold differential with soft-jawed vise. Install final gear. Place offset side of final gear flange toward differential case. Tighten final gear bolts to 65 ft. lbs. (90 N.m). DO NOT substitute final gear bolts.

Fig 1: Exploded View Of Differential Gear

Courtesy of SUZUKI OF AMERICA CORP.