Differential Gear Assembly Removal and Installation: Installation

Bearing outer race 

1. Install differential side right bearing race (1) and shim (2) to transaxle case (3), using special tool.

   Special Tool 

   (A): 09924-07710 

   Fig 1: Identifying Differential Side Right Bearing Race & Shim

   Courtesy of SUZUKI OF AMERICA CORP.
2. Install differential side left bearing race (1) to transaxle housing (2), using special tool.

   Special Tool 

   (A): 09924-07710 

   Fig 2: Identifying Differential Side Left Bearing Race To Transaxle Housing

   Courtesy of SUZUKI OF AMERICA CORP.

Final gear 

1. Heat final gear to about 100°C (212°F) in oil bath.
2. Clean mating surfaces of final gear and differential case.
   Fig 3: Heating Final Gear

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install final gear (1) to differential case (2).
4. Install new 4 final gear set bolt lock plates and 8 bolts and tighten bolts to specified torque.

   Tightening torque 

   Final gear bolts a: 99 N.m (9.9 kg-m, 72.0 lb-ft) 

5. Clamp bolts with lock plate (3) securely.
   Fig 4: Identifying Final Gear To Differential Case

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install differential assembly to transaxle case and tighten case bolts to specified torque.

   Tightening torque 

   Transaxle housing bolts: 30 N.m (3.0 kg-m, 22.0 lb-ft) 

7. Measure differential assembly starting torque, using special tool. If starting torque exceeds specified value, replace shim in the following so as starting torque to be in standard value.

   Special Tool 

   (A): 09928-06060 

   Starting torque of differential assembly 

   0.7 - 1.2 N.m (0.07 - 0.12 kgf-m, 0.506 - 0.868 lb-ft) 

   Fig 5: Measuring Differential Assembly Starting Torque

   Courtesy of SUZUKI OF AMERICA CORP.

   Available differential side bearing shim thickness (Thickness: Identification) 

   BEARING SHIM THICKNESS SPECIFICATION
   
   

   1.00 mm (0.039 in.): 21	1.48 mm (0.058 in.): 33
   1.05 mm (0.041 in.): 22	1.51 mm (0.059 in.): 34
   1.10 mm (0.043 in.): 23	1.54 mm (0.060 in.): 35
   1.15 mm (0.045 in.): 24	1.57 mm (0.061 in.): 36
   1.20 mm (0.047 in.): 25	1.60 mm (0.062 in.): 37
   1.25 mm (0.049 in.): 26	1.65 mm (0.064 in.): 38
   1.30 mm (0.051 in.): 27	1.70 mm (0.066 in.): 39
   1.33 mm (0.052 in.): 28	1.75 mm (0.068 in.): 40
   1.36 mm (0.053 in.): 29	1.80 mm (0.070 in.): 41
   1.39 mm (0.054 in.): 30	1.85 mm (0.072 in.): 42
   1.42 mm (0.055 in.): 31	1.90 mm (0.074 in.): 43
   1.45 mm (0.057 in.): 32