Assembling Unit

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Apply gear oil to differential side bearing, place differential side bearing outer races on their respective bearings, and install differential case assembly in differential carrier.
Measure distance "a" and "b".
1. "a" - "b" = Right side shim(s) + Left side shim(s)
Select shim(s) for right and left sides and install them between differential carrier and differential bearing outer races.
NOTE: Two 2.0 mm (0.079 in.) shims for the left side and two 3.0 mm (0.118 in.) shims for the right side are installed as standard. Therefore, choose shims which are close to the ones mentioned above. For example, if "a" - "b" is 10.05 mm (0.396 in.), combination pattern is as follows.

Fig 1: Side Bearing Shim Chart
Courtesy of SUZUKI OF AMERICA CORP.

Available shim(s)
1. Right side: 1.75, 1.85, 1.95, 2.00, 2.05, 2.15 and 2.25 mm (0.069, 0.073, 0.077, 0.079, 0.081, 0.085 and 0.089 in.)
2. Left side: 2.75, 2.85, 2.95, 3.00, 3.05, 3.15 and 3.25 mm (0.108, 0.112, 0.116, 0.118, 0.120, 0.124 and 0.128 in.)
Fig 2: Measuring Distance "A" & "B"
Courtesy of SUZUKI OF AMERICA CORP.
Measure bevel gear backlash by using dial gauge. If backlash is out of range, repeat from step 3 .
1. Drive bevel gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in.)
NOTE:
- Before measurement, hit shims lightly for several times by plastic hammer to position shims in correct position.
- Be sure to apply measuring tip of dial gauge at right angles to convex side (drive side) of tooth.
- Measure at least 4 points on drive bevel gear periphery.
- If backlash is out of specification, change shim(s) so that backlash is within specification.
Fig 3: Measuring Bevel Gear Backlash Using Dial Gauge
Courtesy of SUZUKI OF AMERICA CORP.
Install axle lock actuator mounting bolts.

Fig 4: Installing Axle Lock Actuator Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Assemble differential carrier cover and differential carrier temporarily.
NOTE: Tighten 12 mm thread diameter bolts (1) first, then loosen 8 mm thread diameter bolts (2).

Tightening torque
1. Front differential cover bolt (12 mm) (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)
2. Front differential cover bolt (8 mm) (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
Fig 5: Assembling Differential Carrier Cover & Differential Carrier Temporarily
Courtesy of SUZUKI OF AMERICA CORP.
Measure preload of pinion with spring balance (1) or torque wrench (2), and then check composite preload of pinion bearing and side bearing.
NOTE:
- Standard preload is shown in graph, which should be read as follows.
  Example: When preload of pinion is 2.6 kg / 5.73 lb, acceptable composite preload of both pinion bearings and differential side bearings should be between 2.8 and 3.2 kg / 6.17 and 7.05 lb.
  
  Special tool
  1. (D): 09922-75222
  Fig 6: Checking Composite Preload Of Pinion Bearing & Side Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
- Spring 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.
  Special tool
  1. (E): 09922-66021
  Fig 7: Checking Preload Using Flange Holder
  Courtesy of SUZUKI OF AMERICA CORP.
- Repeat differential side bearing adjustment until gear backlash and composite bearing preload are compatible within specification.
Fig 8: Gear Backlash & Composite Bearing Preload Chart
Courtesy of SUZUKI OF AMERICA CORP.
As final step, check gear tooth contact as follows.
1. After cleaning tooth surface of 10 bevel gears, paint them with gear marking compound evenly by using brush (1) or sponge etc.
  
  Fig 9: Applying Gear Marking Compound
  Courtesy of SUZUKI OF AMERICA CORP.
2. Assemble differential carrier cover and differential carrier temporarily.
  NOTE: Tighten 12 mm thread diameter bolts (1) first, and then loosen 8 mm thread diameter bolts (2).
  
  Tightening torque
  1. Front differential cover bolt (12 mm) (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)
  2. Front differential cover bolt (8 mm) (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
  Fig 10: Assembling Differential Carrier Cover & Differential Carrier Temporarily
  Courtesy of SUZUKI OF AMERICA CORP.
3. Turn gear to bring its painted part in mesh with pinion and turn it back and forth by hand to repeat their contact.
4. Remove cover bolts (1, 2) and differential carrier cover.
  NOTE: Loosen 8 mm thread diameter bolts (2) first, and then loosen 12 mm thread diameter bolts (1)
  
  Fig 11: Removing Differential Carrier Cover
  Courtesy of SUZUKI OF AMERICA CORP.
5. 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 12: Tooth Contact Pattern Chart
Courtesy of SUZUKI OF AMERICA CORP.
Upon completion of gear tooth contact check in Step 8), clean mating surfaces of both cover and carrier and apply sealant "A" to cover side evenly.
1. "A": Sealant 99000-31110
Fig 13: Applying Sealant To Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install differential carrier cover to differential carrier.
NOTE: Tighten 12 mm thread diameter bolts (1) first, and then loosen 8 mm thread diameter bolts (2).

Tightening torque
1. Front differential cover bolt (12 mm) (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)
2. Front differential cover bolt (8 mm) (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
Fig 14: Installing Differential Carrier Cover To Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Install axle lock actuator motor onto differential carrier cover.
1. "A": Grease 99000-25010
Fig 15: Installing Axle Lock Actuator Motor
Courtesy of SUZUKI OF AMERICA CORP.
Install front drive shaft case (1) to differential housing (2).
"A": Sealant 99000-31110

Tightening torque
1. Front drive shaft case bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)
Fig 16: Installing Front Drive Shaft Case To Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.
Install front mounting bracket R (1) onto differential housing (2).
"A": Sealant 99000-31110

Tightening torque
1. Front mounting bracket bolt (a): 50 N.m (5.0 kg-m, 36.5 lb-ft)
Fig 17: Installing Front Mounting Bracket R Onto Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.