Differential Disassembly and Assembly: Assembly

Install the speedometer drive gear onto the differential gear housing using the installer KM-525.

Fig 1: Installing The Speedometer Drive Gear
Courtesy of SUZUKI OF AMERICA CORP.
Install both of the differential bearings using the installer KM-522.

Fig 2: Installing The Differential Bearings
Courtesy of SUZUKI OF AMERICA CORP.
Install the side gears and the side thrust washers into the differential housing.
Install the differential pinion gears and the differential pinion gear washers into the differential housing.

Fig 3: Installing The Differential Pinion Gears
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion gear shaft into the differential housing.

Fig 4: Installing The Pinion Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.

Fig 5: Installing The Pinion Gear Shaft Lock Pin
Courtesy of SUZUKI OF AMERICA CORP.
Install the ring gear and the ring-gear bolts.
Tighten

Tighten the ring-gear bolts to 70 N.m (52 lb-ft).

Fig 6: Installing The Ring Gear
Courtesy of SUZUKI OF AMERICA CORP.
Install the differential assembly into the transaxle case.

Fig 7: Installing The Differential Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install the right-side bearing retainer and the rightside bearing retainer bolts.
Tighten

Tighten the right-side bearing retainer bolts to 25 N.m (18 lb-ft).

Fig 8: Installing The Right-Side Bearing Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Install the bearing-adjusting ring.
Tighten the bearing-adjusting ring using the remover/installer KM-520.
Tighten

Tighten the bearing adjusting ring until there is no end play with the differential.

Adjust the preload on the differential bearings.

Used Bearings:

1 N.m (9 lb-in) required to rotate the differential one revolution per second.

New Bearings:

2 N.m (18 lb-in) required to rotate the differential one revolution per second.

Tighten or loosen the bearing ring adjuster to get the required preload on the bearings.

Fig 9: Tightening The Bearing-Adjusting Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install the bearing-adjusting ring-retainer plate and the bearing-adjusting ring-retainer plate bolt.
Tighten

Tighten the bearing-adjusting ring-retainer plate bolt to 5 N.m (44 lb-in).

Fig 10: Installing The Bearing-Adjusting Ring-Retainer Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install the differential cover gasket, the differential cover, and the differential cover bolts.
Tighten

Tighten the differential cover bolts to 40 N.m (30 lb-ft).

Fig 11: Installing The Differential Cover Gasket
Courtesy of SUZUKI OF AMERICA CORP.