Differential Disassembly and Assembly: Assembly

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

Fig 1: Identifying Installer KM-525
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Install both of the differential bearings using the installer KM-522.

Fig 2: Identifying Installer KM-522
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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: Holding Pinion Gears
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Install the pinion gear shaft into the differential housing.

Fig 4: Identifying Pinion Gear Shaft
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Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.

Fig 5: Identifying Pinion Gear Shaft
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Install the ring gear and the ring-gear bolts.
Tighten:

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

Fig 6: Tightening 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: Tightening 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: Identifying Remover/Installer KM-520
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
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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.