Assembling Unit

Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
Install case assembly in carrier.
Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.

Fig 1: Installing Case Assembly In Carrier
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Align match marks (1) on cap and carrier. Screw in 2 side bearing cap bolts 2 or 3 turns and press down bearing cap by hand.
NOTE: If bearing cap does not fit tightly on carrier, side bearing adjuster is not threaded properly. Reinstall adjuster.
Tighten cap bolts (provisional torque).
Tightening torque

Bearing cap bolt (provisional torque) (a): 15 N.m (1.5 kg-m, 11.0 lb-ft)

Fig 2: Tightening Cap Bolts
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Tighten both bearing adjusters (2) so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- As a practical measure the following would be recommended to obtain specified backlash and side bearing preload at the same time.
  1. Obtain specified backlash by turning both adjusters inward lightly.
  2. Tighten both adjusters further by one notch at a time.
- Measure at least 4 points on drive bevel gear periphery.
Standard backlash: 0.13 - 0.18 mm (0.005 - 0.007 in.)

Special tools

(A): 09930-40120

(B): 09930-40113

(C): 09900-20701

Fig 3: Tightening Both Bearing Adjusters To Obtain Specified Gear Backlash
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Measure preload of pinion with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing.
NOTE:
- Standard preload is shown in graph on next page, which should be read as follows.
  Example:
  
  When preload of bevel pinion is 26 N (2.6 kg, 5.73 lb), acceptable composite preload of both pinion bearings and side bearings should be between 2.8 and 3.2 kg / 6.17 and 7.05 lb.
  
  Special tool
  
  (D): 09922-75222
  
  Fig 4: Checking Composite Preload Of Pinion Bearing & Side Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
- Bearing preload can be checked roughly by using flange holder as shown in the figure. In this measurement, holder arm itself will work as balance weight and torque will be replaced with angle. However, flange should be rotated very slowly with hand support so as not to allow over revolution due to inertia.
- Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specification, if failed to obtain specified measurements first.
Special tool

(E): 09922-66020

Fig 5: Checking Bearing Preload Using Flange Holder
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Fig 6: Gear Backlash & Composite Bearing Preload Chart
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Torque bearing cap bolts (2) to specification and install bearing lock plates.
Tightening torque

Lock plate bolt (b): 12 N.m (1.2 kg-m, 9.0 lb-ft)

Bearing cap bolt (c): 85 N.m (8.5 kg-m, 61.5 lb-ft)

Fig 7: Torquing Bearing Cap Bolts & Installing Bearing Lock Plates
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As final step, check gear tooth contact as follows.
1. After cleaning 10 bevel gear teeth, paint them with gear marking compound evenly by using brush or sponge etc.
2. Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact.
3. Bring painted part up and check contact pattern, referring to the following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.
NOTE: Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.

Fig 8: Applying Gear Marking Compound
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Fig 9: Tooth Contact Pattern Chart (1 Of 2)
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Fig 10: Tooth Contact Pattern Chart (2 Of 2)
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Upon completion of gear tooth contact check in previous step, caulk flange nut (2) with caulking tool (1) and hammer.

Fig 11: Caulking Flange Nut

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