Differential Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

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 Both Of 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: Installing Pinion Gear Shaft Into Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.

Fig 5: Installing Pinion Gear Shaft Lock Pin Into Differential Housing
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: Installing Differential Assembly Into Transaxle Case
Courtesy of SUZUKI OF AMERICA CORP.
Install the right-side bearing retainer and the rightside bearing retainer bolts.
Tighten

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

Fig 8: Installing Rightside 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: Installing 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: Installing Bearing-Adjusting Ring-Retainer Plate
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: Installing Differential Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.