Extension Case Disassembly And Reassembly: Reassembly

Install intermediate front bearing (1) and/or intermediate rear bearing (2) using press (3) and bearing puller (4).

Fig 1: Identifying Bearing Puller On Intermediate Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install oil seal (1) to front extension case (2) until it become flush with case using special tool, and then apply grease to oil seal lip.
NOTE: When installing oil seal, face its spring side inward.

"A": Grease 99000-25010SUZUKI Super Grease A

Special Tool
1. 09951-46010
  
  Fig 2: Identifying Front Extension Case With Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Install intermediate shaft with bearings to front extension case.
Assemble rear extension case (2) as follows.
1. Install needle bearing (1) to rear extension case until it become flush with case using special tool.
  Special Tool
  1. 09913-75520
  Fig 3: Identifying Needle Bearing To Rear Extension Case With Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
2. Install oil seal (1) to rear extension case (2) until it become flush with case using special tool, and then apply grease to oil seal lip.
  "A": Grease 99000-25010SUZUKI Super Grease A
  
  Special Tool
  1. 09913-75510
    
    Fig 4: Identifying Oil Seal To Rear Extension Case With Special Tool
    Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surfaces of front extension case and rear extension case (1), apply sealant to rear extension case as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate rear extension case with front extension case, and then tighten bolts to specified torque.
"A": Sealant 99000-31260SUZUKI Bond No.1217G

Tightening torque

Extension case bolt: 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 5: Identifying Area Applying Sealant To Rear Extension Case
Courtesy of SUZUKI OF AMERICA CORP.