Assembling Unit

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
Install case assembly in carrier.

Fig 1: Installing Case Assembly In Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.
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
Courtesy of SUZUKI OF AMERICA CORP.
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.
  - Obtain specified backlash by turning both adjusters inward lightly.
  - 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 tool
1. (A): 09930-40120
2. (B): 09930-40113
3. (C): 09900-20701
  
  Fig 3: Tightening Both Bearing Adjusters To Obtain Specified Gear Backlash
  Courtesy of SUZUKI OF AMERICA CORP.
For H25 engine model
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 below, which should be read as follows.
  Example:
  1. 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
  1. (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 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
1. (E): 09922-66021
Fig 5: Checking Bearing Preload Using Flange Holder
Courtesy of SUZUKI OF AMERICA CORP.

Fig 6: Gear Backlash & Composite Bearing Preload Chart
Courtesy of SUZUKI OF AMERICA CORP.
For H27 engine model
Measure preload of pinion bearing with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing.
NOTE:
- Before taking measurement with spring balance (1) or torque wrench (2), check for smooth rotation by hand.
- On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
Composite preload of pinion bearing and side bearing: 1.1 - 2.0 N.m (11.0 - 20.0 kg-cm, 9.5 - 17.4 lb-in.)

Spring measure reading with special tool: 19.5 - 35.5 N (1.95 - 3.55 kg, 4.30 - 7.83 lb)

Special tool

(D): 09922-76560

Fig 7: Checking Composite Preload Of Pinion Bearing & Side Bearing
Courtesy of SUZUKI OF AMERICA CORP.
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 8: Installing Bearing Cap Bolts
Courtesy of SUZUKI OF AMERICA CORP.
As final step, check gear tooth contact as follows.
1. After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
2. Turn gear to bring its painted part in mesh with drive 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 table. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table.
NOTE: Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

Fig 9: Applying Gear Marking Compound
Courtesy of SUZUKI OF AMERICA CORP.

Fig 10: Tooth Contact Pattern Chart
Courtesy of SUZUKI OF AMERICA CORP.
Upon completion of gear tooth contact check in Step 10), caulk flange nut (2) with caulking tool (1) and hammer.

Fig 11: Caulking Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.