Drive Bevel Pinion

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

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

   • This installation requires no spacer and 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 

   (A): 09922-75222 

   (B): 09926-78311 

   (C): 09951-46010 

   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: Identifying Flange Nut, Spring Balance, Torque Wrench, Socket With Adapter & Special Tools

   Courtesy of SUZUKI OF AMERICA CORP.
2. Set dial gauge to 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, roll dummy back and force by hand once or twice, and then attain accurate 0 (zero) adjustment.
   • It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).

   Special Tool 

   (C): 09926-78320 

   (D): 09900-20607 

   Fig 2: Identifying Surface Plate, Screw & Special Tools

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

   • Roll dummy back and force by hand once or twice, and then measure distance to the top surface of pinion dummy accurately.
   • When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.

   Special Tool 

   (B): 09926-78311 

   (C): 09926-78320 

   (D): 09900-20607 

   (E): 09922-76570 

   Fig 3: Identifying Special Tools On Pinion

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

   Special Tool 

   (A): 09900-20607 

   (B): 09926-78320 

   (C): 09922-75222 

   (D): 09926-78311 

   (E): 09922-76570 

   (F): 09951-46010 

   Fig 4: Identifying Front Differential Components & Measurements

   Courtesy of SUZUKI OF AMERICA CORP.
5. Select shim(s) (2) closest to calculated value and put it in place. And then, press-fit front bearing (1).

   Special Tool 

   (E): 09913-85210 

   (F): 09927-66010 

   Available shims 

   1.00, 1.03, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 and 0.3 mm (0.039, 0.041, 0.043, 0.044, 0.045, 0.046, 0.048, 0.049, 0.050, 0.051 and 0.012 in.) 

   Fig 5: Identifying Pinion, Shims & Front Bearing

   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: Identifying Bevel Pinion, Front Bearing, Pinion Spacer, Rear Bearing & Differential Carrier

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

   Special Tool 

   (G): 09951-18210 

   "A": Grease 99000-25010 

   Fig 7: Identifying Oil Seal & 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. The use of 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 

   (A): 09922-75222 

   (H): 09922-66021 

   Fig 8: Identifying Power Wrench, Spring Balance, Torque Wrench & Socket Wrench

   Courtesy of SUZUKI OF AMERICA CORP.