Differential Unit

Install side oil seal to bearing outer race (1).
Then apply grease to oil seal lip.

: Grease 99000-25010

Special tool

(A): 09913-75520

Fig 1: Installing Side Oil Seal To Bearing Outer Race
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Place bearing outer races (1) on their respective bearings.
NOTE: Used left and right outer races are not interchangeable.
After applying differential oil to side bearings, install case assembly (2) in differential carrier (3).

Fig 2: Installing Case Assembly In Differential Carrier
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Tighten bearing retainer.
Special tool

(B): 09923-58520

Fig 3: Tightening Bearing Retainer
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To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion, tighten both retainers and read dial gauge while moving bevel gear.
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- As a practical measure following would be recommended to obtain specified backlash and side bearing preload at the same time.
  - Obtain specified backlash by turning both retainers inward lightly.
  - Tighten both retainers further by one notch at a time.
- Measure at least 4 points on drive bevel gear periphery.
Special tool

(C): 09900-20606

: 09923-58520

: 09900-20701

Drive bevel gear backlash

Standard: 0.1 - 0.2 mm (0.004 - 0.008 in.)

Fig 4: Measuring Bevel Gear Backlash
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With bevel gear installed, measure rotational torque while turning bevel pinion about 50 RPM by using special tool.
Special tool

(E): 09922-75222

Differential side bearing preload:

(Measured bevel pinion bearing preload) + (3 - 5 kg-cm (2.6 - 4.3 lb-in))

Rotational force with special tool:

(Measured bevel pinion bearing preload) + (0.6 - 1 kg (1.3 - 2.2 lb))

Fig 5: Measuring Rotational Torque
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Install retainer stoppers (2).
NOTE: Change shape of retainer stopper depending on position of tooth on retainer (1).

Tightening torque

Retainer stopper bolts (a): 10 N.m (1.0 kg-m, 7.5 Ft.Lbs.)

Fig 6: Installing Retainer Stoppers
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Check gear tooth contact.
Apply red lead paste to tooth of drive bevel gear and turn it by hand to check its contact with drive bevel pinion. Check contact pattern, referring to following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.
NOTE:
- Apply red lead paste all around bevel gear but not so much as to become sticky.
- Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
Fig 7: Gear Tooth Contact Table (1 of 2)
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Fig 8: Gear Tooth Contact Table (2 of 2)
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Upon completion of gear tooth contact check in Step 8 , after applying sealant to breather cover (3), install breather plug (2) to differential cover (4).
After applying sealant to differential cover (4), install differential cover (4) to differential carrier (1).
"A": Sealant 99000-31110

Tightening torque

Breather cover bolt (b): 6.0 N.m (0.6 kg-m, 4.5 Ft.Lbs.)

Differential cover bolts: 23 N.m (2.3 kg-m, 17.0 Ft.Lbs.)

Fig 9: Installing Differential Cover To Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Caulk bevel pinion nut (2) with caulking tool (1) and hammer.

Fig 10: Caulking Bevel Pinion Nut
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