Drive Bevel Pinion

To engage bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described below. Shown in the figure of Step  4 are relative positions of bevel pinion, differential carrier and mounting dummy.

1. Install bevel pinion dummy with bearings into differential carrier and tighten flange nut (1) so that specified bearing preload is obtained.
   NOTE:

   • This installation requires universal joint flange not equipped with groove on flange periphery.
   • This installation requires no spacer or oil seal.
   • Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of oil to bearings.

   Special tool 

   1. (A):  09922-75222
   2. (B):  09926-78311

   Pinion bearing preload (a):  0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in)

   Spring measure reading:  1.8 - 3.4 kg (4.0 - 7.5 lb)

   Fig 1: Checking Bearing Preload

   Courtesy of SUZUKI OF AMERICA CORP.
2. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate.
   NOTE:

   • When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge.
   • With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.
   • It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).

   Special tool 

   1. (C):  09926-78311
   2. (D):  09900-20607
   Fig 2: Making 0 (Zero) Adjustment To Bevel Pinion Mounting Dummy On Surface Plate

   Courtesy of SUZUKI OF AMERICA CORP.
3. Place zero-adjusted mounting dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip.
   NOTE:

   • Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurately.
   • When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
   • Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.

   Special tool 

   1. (C):  09926-78311
   2. (D):  09900-20607
   Fig 3: Using Pinion Mounting Dummy To Measure Between Zero Position & Extended Dial Gauge Measuring Tip

   Courtesy of SUZUKI OF AMERICA CORP.
4. Obtain adjusting shim thickness by using measured value by dial gauge (which represents "c" in figure) in the following equation.

   94 in above equation is "a" + "b" of mounting dummy (special tool) as shown in the figure.

   Special tool 

   1. (A):  09900-20607
   2. (B):  09926-78311
   3. (C):  09922-75222
   Fig 4: Measuring For Pinion Adjusting Shim

   Courtesy of SUZUKI OF AMERICA CORP.
5. Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit front bearing (1).

   Special tool 

   1. (E):  09925-18011
   2. (F):  09927-66010

   Available shim thickness:  1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 & 0.3 mm (0.044, 0.045, 0.046, 0.048 0.049, 0.050, 0.051 & 0.012 in.)

   Fig 5: Pressing Adjusting Shim & Bearing On Pinion

   Courtesy of SUZUKI OF AMERICA CORP.
6. With new pinion spacer (3) inserted as shown, install rear bearing (5) to differential carrier (4).
   NOTE:

   • Make sure to use new spacer for reinstallation.
   • Apply oil to bearings.
   Fig 6: Installing Pinion Into Differential Carrier

   Courtesy of SUZUKI OF AMERICA CORP.
7. Using special tool and plastic hammer drive oil seal (2) into differential carrier (1) till it becomes flush with carrier end. Then apply grease to oil seal lip.

   Special tool 

   1. (G):  09951-18210
   2. "A":  Grease 99000-25010
   Fig 7: Installing Seal Into Differential Carrier

   Courtesy of SUZUKI OF AMERICA CORP.
8. While tightening flange nut gradually with flange holder (special tool) and power wrench (4-10 magnification) (1), set preload of pinion to specification.
   NOTE:

   • Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand.
   • Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange.
   • Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.

Pinion bearing preload:  0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in)

Spring measure reading:  1.8 - 3.4 kg (4.0 - 7.5 lb)

Special tool 

1. (A):  09922-75222
2. (H):  09922-66021

Fig 8: Tightening Flange Nut To Set Bearing Preload

Courtesy of SUZUKI OF AMERICA CORP.