Differential Disassembly and Assembly: Assembly

Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly. Make sure that all parts are clean.

1. Assemble differential gear and measure thrust play of differential gear as follows.

   Special Tool 

   1. 09900-20607 
   2. 09900-20701 

   Differential gear thrust play 

   0.05 - 0.33 mm (0.002 - 0.013 in.) 

   Left side 

   • Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to top surface of gear (2).
   • Using 2 screwdrivers (1), move gear up and down and read movement of dial gauge pointer.

   Right side 

   • Using similar procedure to the left side, set dial gauge tip to gear (2) shoulder.
   • Move gear up and down by hand and read dial gauge.
2. If thrust play is out of specification, select suitable thrust washer from among the following available size, install it and check again that specified gear play is obtained.

   Available differential gear thrust washer thickness 

   DIFFERENTIAL GEAR THRUST WASHER THICKNESS SPECIFICATIONS
   
   

   0.85 mm (0.033 in.)	1.05 mm (0.041 in.)
   0.9 mm (0.035 in.)	1.1 mm (0.043 in.)
   0.95 mm (0.037 in.)	1.15 mm (0.045 in.)
   1.0 mm (0.039 in.)

3. Drive in spring pin from right side till it is flush with differential case surface.
   Fig 1: Setting Dial Gauge Tip To Gear Shoulder

   Courtesy of SUZUKI OF AMERICA CORP.
4. Press-fit left bearing (1) by using special tool and copper hammer.

   Special Tool 

   1. 09951-76010 
      Fig 2: Installing Left Bearing By Using Special Tool And Copper Hammer

      Courtesy of SUZUKI OF AMERICA CORP.
5. Press-fit new sensor rotor (1) with groove (2) down word using special tools and copper hammer.

   Special Tool 

   1. 09924-74510 
   2. 09926-27610 
   3. 09926-37610-003 
      Fig 3: Installing Sensor Rotor With Groove

      Courtesy of SUZUKI OF AMERICA CORP.
6. Press-fit right bearing (1) by using special tools and copper hammer.

   Special Tool 

   1. 09913-76010 
   2. 09926-37610-003 
      Fig 4: Installing Right Bearing By Using Special Tools And Copper Hammer

      Courtesy of SUZUKI OF AMERICA CORP.
7. Hold differential assembly with soft jawed vise (3), install final gear (2) and then tighten final gear bolts (1), to which thread lock cement has been applied, to specified torque.

   Apply thread lock cement to bolt thread when reusing bolts.

   CAUTION: Use of any other bolts than specified ones is prohibited.

   "A": Thread lock cement 99000-32110 

   Tightening torque 

   Final gear bolt a: 90 N.m (9.0 kg-m, 65.0 lb-ft) 

   Fig 5: Installing Final Gear Bolts

   Courtesy of SUZUKI OF AMERICA CORP.