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.

Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
Install case assembly in carrier.
Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.

Fig 1: Installing Case Assembly In Carrier
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Align match marks (1) on cap and carrier. Screw in 2 side bearing cap bolts 2 or 3 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 (provisional torque).
Tightening torque

Bearing cap bolt (Provisional torque) a: 15 N.m (1.5 kg-m, 11.0 lb-ft)

Fig 2: Identifying Match Marks & Bearing Cap Bolts
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Tighten both bearing adjusters (2) so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- As a practical measure the following would be recommended to obtain specified backlash and side bearing preload at the same time.
  - Obtain specified backlash by turning both adjusters inward lightly.
  - Tighten both adjusters further by one notch at a time.
- Measure at least 4 points on drive bevel gear periphery.
Standard backlash

0.13 - 0.18 mm (0.005 - 0.007 in.)

Special Tool

(A): 09930-40120

(B): 09930-40113

(C): 09900-20701

Fig 3: Identifying Bearing Adjusters, Bearing Cap Bolt & Special Tools
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Measure preload of pinion bearing with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing.
NOTE:
- Before taking measurement with spring balance (1) or torque wrench (2), check for smooth rotation by hand.
- On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
Composite preload of pinion bearing and side bearing

1.1 - 2.0 N.m (11.0 - 20.0 kg-cm, 9.5 - 17.4 lb-in.)

Spring measure reading with special tool

19.5 - 35.5 N (1.95 - 3.55 kg, 4.30 - 7.83 lb)

Special Tool

(D): 09922-76560

Fig 4: Identifying Universal Joint Flange, Socket With Adapter, Spring Balance, Torque Wrench & Special Tool
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Torque bearing cap bolts (2) to specification and install bearing lock plates.
Tightening torque

Lock plate bolt b: 12 N.m (1.2 kg-m, 9.0 lb-ft)

Bearing cap bolt c: 85 N.m (8.5 kg-m, 61.5 lb-ft)

Fig 5: Identifying Lock Plate Bolt And Bearing Cap Bolt
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As final step, check gear tooth contact as follows.

After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact.
Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table.

NOTE: Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

Fig 6: Identifying Brush & Drive Bevel Gear Teeth

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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 drive bevel gear (1). Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. Adjust drive 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 drive bevel gear (1). Decrease thickness of pinion (1) height adjusting shim and position pinion farther from gear center. Adjust drive 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 drive bevel gear and pinion set or differential carrier.
Courtesy of SUZUKI OF AMERICA CORP.	Replace drive bevel gear and pinion set or differential case.

Upon completion of gear tooth contact check in Step 9, caulk flange nut (2) with caulking tool (1) and hammer.

Fig 7: Identifying Flange Nut, Caulking Tool & Hammer
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