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 sealant "A" to thread part of air inlet union (2) and install it to differential carrier (1). Tighten it to specified torque
"A": Sealant 99000-31110

Tightening torque
1. Air inlet union (a): 13 N.m (1.3 kg-m, 9.5 lb-ft)
Fig 1: Installing Air Inlet Union Into Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable and install case assembly in carrier.
Install side bearing adjusters on their respective carrier, making sure adjusters are threaded properly.
Align match marks (1) on cap and carrier. Screw in two side bearing cap bolts two or three 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 to provisional torque below.
Tightening torque
1. Side bearing cap bolt (provisional torque) (a): 15 N.m (1.5 kg-m, 11.0 lb-ft)
Install actuator bracket to bearing cap and tighten its bolts to specification.
Tightening torque
1. Actuator bracket bolt (b): 12 N.m (1.2 kg-m, 9.0 lb-ft)
Fig 2: Installing Case Assembly In Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Tighten both bearing adjusters (1) so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.
Special tool
1. (A): 09930-40120 (Attachment)
2. (B): 09930-40113 (Rotor holder)
3. (C): 09900-20701
4. Bevel gear backlash: 0.13 - 0.18 mm (0.005 - 0.007 in.)
Fig 3: Setting Gear Backlash & Preload Of Side Bearing
Courtesy of SUZUKI OF AMERICA CORP.
NOTE:
- Be sure to apply measuring tip of dial gauge (1) at right angles to convex side of tooth.
- Measure at least 4 points on drive bevel gear periphery.
- As a practical measure the following would be recommended to obtain specified backlash and side bearing preload at the same time.
  1. Obtain specified backlash by turning both adjusters inward lightly.
  2. Tighten both adjusters further by one notch at a time.
Fig 4: Measuring Gear Backlash
Courtesy of SUZUKI OF AMERICA CORP.
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 on next page, which should be read as follows.
  Example: When preload of bevel pinion is 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 5: 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 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 6: Checking Bearing Preload Using Flange Holder
  Courtesy of SUZUKI OF AMERICA CORP.
- Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specification, if fail to obtain specified measurements first.
Fig 7: Gear Backlash/Composite Bearing Preload Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.
Torque bearing cap bolts to specification and install bearing lock plates.
Tightening torque
1. Bearing cap bolt (a): 60 N.m (6.0 kg-m, 43.5 lb-ft)
2. Lock plate bolt (b): 13 N.m (1.3 kg-m, 9.5 lb-ft)
Fig 8: Installing Bearing Lock Plates
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.
2. Turn gear to bring its painted part in mesh with 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 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 9: Applying Gear Marking Compound To Bevel Gears
Courtesy of SUZUKI OF AMERICA CORP.

Fig 10: Tooth Contact Pattern Chart (1 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.

Fig 11: Tooth Contact Pattern Chart (2 Of 2)
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 12: Caulking Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surfaces of both housing and carrier and apply sealant "A" to housing side evenly.
1. "A": Sealant 99000-31110
Fig 13: Applying Sealant To Housing
Courtesy of SUZUKI OF AMERICA CORP.
With differential assembly installed in housing, position it with 2 reamer bolts (2) and then install other 6 bolts (1).
Torque all bolts to specification.
Tightening torque
1. Differential carrier bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
Fig 14: Installing Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Install front drive shaft.