Assembling Unit

WARNING: This page is about a different car, the 2006 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.

Apply gear oil to differential side bearing, place differential side bearing outer races on their respective bearings, and install differential case assembly in differential carrier.
Measure distance "a" and "b".

Select shim(s) for right and left sides and install them between differential carrier and differential bearing outer races.

NOTE: Two 2.0 mm (0.079 in.) shims for the left side and two 3.0 mm (0.118 in.) shims for the right side are installed as standard. Therefore, choose shims which are close to the ones mentioned above. For example, if "a"-"b" is 10.05 mm (0.396 in.), combination pattern is as follows.

PATTERN CHART

Pattern	Right side	Left side
1	1.75 mm (0.069 in.), 2.25 mm (0.089 in.)	3.00 mm (0.118 in.), 3.05 mm (0.120 in.)
2	1.85 mm (0.073 in.), 2.15 mm (0.085 in.)	3.00 mm (0.118 in.), 3.05 mm (0.120 in.)
3	1.95 mm (0.077 in.), 2.05 mm (0.081 in.)	3.00 mm (0.118 in.), 3.05 mm (0.120 in.)
4	2.00 mm (0.079 in.), 2.00 mm (0.079 in.)	3.00 mm (0.118 in.), 3.05 mm (0.120 in.)
5	2.00 mm (0.079 in.), 2.05 mm (0.081 in.)	2.75 mm (0.108 in.), 3.25 mm (0.128 in.)
6	2.00 mm (0.079 in.), 2.05 mm (0.081 in.)	2.85 mm (0.112 in.), 3.15 mm (0.124 in.)
7	2.00 mm (0.079 in.), 2.05 mm (0.081 in.)	2.95 mm (0.116 in.), 3.05 mm (0.120 in.)
8	2.00 mm (0.079 in.), 2.05 mm (0.081 in.)	3.00 mm (0.118 in.), 3.00 mm (0.118 in.)

Available shim(s)

Right side

1.75, 1.85, 1.95, 2.00, 2.05, 2.15 and 2.25 mm (0.069, 0.073, 0.077, 0.079, 0.081, 0.085 and 0.089 in.)

Left side

2.75, 2.85, 2.95, 3.00, 3.05, 3.15 and 3.25 mm (0.108, 0.112, 0.116, 0.118, 0.120, 0.124 and 0.128 in.)

Fig 1: Identifying Shim Right/Left Sides Length

Courtesy of SUZUKI OF AMERICA CORP.

Measure bevel gear backlash by using dial gauge. If backlash is out of range, repeat from step 3.
Drive bevel gear backlash

0.10 - 0.20 mm (0.004 - 0.008 in.)
NOTE:
- Before measurement, hit shims lightly for several times by plastic hammer to position shims in correct position.
- Be sure to apply measuring tip of dial gauge at right angles to convex side (drive side) of tooth.
- Measure at least 4 points on drive bevel gear periphery.
- If backlash is out of specification, change shim(s) so that backlash is within specification.
Fig 2: Measuring Bevel Gear Backlash With Dial Gauge
Courtesy of SUZUKI OF AMERICA CORP.
Install axle lock actuator mounting bolts.

Fig 3: Identifying Axle Lock Actuator Mounting Bolts
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Assemble differential carrier cover and differential carrier temporarily.
NOTE: Tighten 12 mm thread diameter bolts (1) first, then loosen 8 mm thread diameter bolts (2).

Tightening torque

Front differential cover bolt (12 mm) a: 85 N.m (8.5 kg-m, 61.5 lb-ft)

Front differential cover bolt (8 mm) b: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 4: Identifying Differential Carrier Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Measure preload of pinion with spring balance (1) or torque wrench (2), and then check composite preload of pinion bearing and side bearing.
NOTE:
- Standard preload is shown in graph, which should be read as follows.
  Example:
  
  When preload of pinion is 2.6 kg / 5.73 lb, acceptable composite preload of both pinion bearings and differential side bearings should be between 2.8 and 3.2 kg / 6.17 and 7.05 lb.
  
  Special Tool
  
  (D): 09922-75222
  
  Fig 5: Identifying Spring Balance, Torque Wrench, Universal Joint Flange, Socket With Adapter & Special Tools
  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
  
  (E): 09922-66021
  
  Fig 6: Identifying Pinion Bearing Starting Torque Range, Pinion Bearing Plus Side Bearing Starting Torque Range & Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
- Repeat differential side bearing adjustment until gear backlash and composite bearing preload are compatible within specification.
  
  Fig 7: Pinion Bearing Starting Torque + Differential Side Bearing Starting Torque Vs Differential Side Bearing Starting Torque Graph
  Courtesy of SUZUKI OF AMERICA CORP.

As final step, check gear tooth contact as follows.

After cleaning tooth surface of 10 bevel gears, paint them with gear marking compound evenly by using brush (1) or sponge etc.

Fig 8: Identifying Brush On Bevel Gear Teeth
Courtesy of SUZUKI OF AMERICA CORP.
Assemble differential carrier cover and differential carrier temporarily.
NOTE: Tighten 12 mm thread diameter bolts (1) first, and then loosen 8 mm thread diameter bolts (2).

Tightening torque

Front differential cover bolt (12 mm) a: 85 N.m (8.5 kg-m, 61.5 lb-ft)

Front differential cover bolt (8 mm) b: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 9: Identifying Front Differential Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Turn gear to bring its painted part in mesh with pinion and turn it back and forth by hand to repeat their contact.
Remove cover bolts (1, 2) and differential carrier cover.
NOTE: Loosen 8 mm thread diameter bolts (2) first, and then loosen 12 mm thread diameter bolts (1)

Fig 10: Identifying Front Differential Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.
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.

TOOTH CONTACT PATTERN REFERENCE CHART

Tooth Contact Pattern	Diagnosis and Remedy
Courtesy of SUZUKI OF AMERICA CORP.	Normal
Courtesy of SUZUKI OF AMERICA CORP.	High Contact Pinion is positioned too far from the center of driver bevel gear. Increase thickness of pinion height adjusting shim and position pinion closer to gear center. Adjust bevel gear backlash to specification.	Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.	Low Contact Pinion is positioned too close to the center of bevel gear. Decrease thickness of pinion height adjusting shim and position pinion farther from gear center. Adjust bevel gear backlash to specification.	Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.	If adjustment is impossible, replace differential carrier.
Courtesy of SUZUKI OF AMERICA CORP.	Check seating of bevel gear or differential case, (Check bevel gear for runout. If adjustment is impossible, replace bevel gear and pinion set or differential carrier.
Courtesy of SUZUKI OF AMERICA CORP.	Replace bevel gear and pinion set or differential case.

Upon completion of gear tooth contact check in Step 8, clean mating surfaces of both cover and carrier and apply sealant "A" to cover side evenly.
"A": Sealant 99000-31110

Fig 11: Identifying Sealant Application Area
Courtesy of SUZUKI OF AMERICA CORP.
Install differential carrier cover to differential carrier.
NOTE: Tighten 12 mm thread diameter bolts (1) first, and then loosen 8 mm thread diameter bolts (2).

Tightening torque

Front differential cover bolt (12 mm) a: 85 N.m (8.5 kg-m, 61.5 lb-ft)

Front differential cover bolt (8 mm) b: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 12: Identifying Front Differential Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install axle lock actuator motor onto differential carrier cover.
"A": Grease 99000-25010

Fig 13: Identifying O-Ring & Grease Application Area
Courtesy of SUZUKI OF AMERICA CORP.
Install front drive shaft case (1) to differential housing (2).
"A": Sealant 99000-31110

Tightening torque

Front drive shaft case bolt a: 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 14: Identifying Front Drive Shaft Case & Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.
Install front mounting bracket R (1) onto differential housing (2).
"A": Sealant 99000-31110

Tightening torque

Front mounting bracket bolt a: 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fig 15: Identifying Front Mounting Bracket & Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.