Differential Disassembly and Assembly: Assembly

Install the speedometer drive gear onto the differential gear housing using the installer KM-525.

Fig 1: Installing Speedometer Drive Gear Onto Differential Gear Housing
Courtesy of SUZUKI OF AMERICA CORP.
Install both of the differential bearings using the installer KM-522.

Fig 2: Installing Differential Bearings
Courtesy of SUZUKI OF AMERICA CORP.
Install the side gears and the side thrust washers into the differential housing.
Install the differential pinion gears and the differential pinion gear washers into the differential housing.

Fig 3: Installing Differential Pinion Gears
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion gear shaft into the differential housing.

Fig 4: Identifying Pinion Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.

Fig 5: Identifying Pinion Gear Shaft Lock Pin And Pinion Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install the ring gear and the ring-gear bolts.
Tighten:

Tighten the ring-gear bolts to 70 N.m (52 lb-ft).

Fig 6: Installing Ring Gear And Ring-Gear Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the differential assembly into the transaxle case.

Fig 7: Identifying Differential Assembly
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Install the right-side bearing retainer and the right-side bearing retainer bolts.
Tighten:

Tighten the right-side bearing retainer bolts to 25 N.m (18 lb-ft).

Fig 8: Installing Right-Side Bearing Retainer Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install the bearing-adjusting ring.
Tighten the bearing-adjusting ring using the remover/installer KM-520.
Tighten:

Tighten the bearing adjusting ring until there is no end play with the differential.

Adjust the preload on the differential bearings.

Used Bearings:

1 N.m (9 lb-in) required to rotate the differential one revolution per second.

New Bearings:

2 N.m (18 lb-in) required to rotate the differential one revolution per second.

Tighten or loosen the bearing ring adjuster to get the required preload on the bearings.

Fig 9: Tightening Bearing-Adjusting Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install the bearing-adjusting ring-retainer plate and the bearing-adjusting ring-retainer plate bolt.
Tighten:

Tighten the bearing-adjusting ring-retainer plate bolt to 5 N.m (44 lb-in).

Fig 10: Identifying Bearing-Adjusting Ring-Retainer Plate Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install the differential cover gasket, the differential cover, and the differential cover bolts.
Tighten:

Tighten the differential cover bolts to 40 N.m (30 lb-ft).

Fig 11: Identifying Differential Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.