Differential Disassembly and Reassembly: Reassembly

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. Install differential pinion, side gear and pinion shaft to differential case and measure back rash and thrust play of differential side gear as follows.

   If measured value is out of specification, select suitable side gear washer from among the following available size, install it and check again.

   Special Tool 

   1. 09900-20607 
   2. 09900-20701 
   3. 09952-06010 
   1. Differential side gear backlash
      • Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to side gear as shown in figure.
      • Fixing differential pinion, turn side gear back and forth and read dial gauge.

        Differential side gear backlash 

        0.10 - 0.15 mm (0.003 - 0.005 in.) 

   2. Differential side gear thrust play
      • Hold differential assembly with soft jawed vise and apply measuring tip of dial gauge to side gear as shown in figure.
      • Move side gear up and down by hand and read dial gauge.

        Differential side gear thrust play 

        0.03 - 0.31 mm (0.001 - 0.012 in.) 

        Available side gear washer thickness 

        SIDE GEAR WASHER THICKNESS CHART
        
        

        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.)	1.20 mm (0.047 in.)
        1.05 mm (0.041 in.)

        Fig 1: Checking Differential Side Gear Thrust Play

        Courtesy of SUZUKI OF AMERICA CORP.
2. Drive in spring pin from right side till it is flush with differential case surface.
3. Press-fit left bearing (1) by using special tool and hydraulic press.

   Special Tool 

   (A): 09913-70123 

   Fig 2: Pressing-Fit Left Bearing

   Courtesy of SUZUKI OF AMERICA CORP.
4. Press-fit right bearing (1) by using special tools and hydraulic press.

   Special Tool 

   1. 09925-15410 
   2. 09924-07720 
   3. 09913-85230 
      Fig 3: Press-Fitting Bearing

      Courtesy of SUZUKI OF AMERICA CORP.
5. Hold differential assembly with soft jawed vise (3), install final gear (2) and then tighten new final gear bolts (1).
   CAUTION: Use of any other bolts than specified ones is prohibited. Otherwise, bolts may loosen.

   Tightening torque 

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

   Fig 4: Holding Differential Assembly With Soft Jawed Vise, Installing Final Gear And Tightening Final Gear Bolts

   Courtesy of SUZUKI OF AMERICA CORP.