Extension Case Disassembly and Reassembly: Reassembly

Reference: EXTENSION CASE ASSEMBLY INSPECTION 

1. Install intermediate front bearing (1) and/or intermediate rear bearing (2) using hydraulic press (3) and bearing puller (4).
   Fig 1: Installing Intermediate Front Bearing And/Or Intermediate Rear Bearing

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2. 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 99000-25011 (SUZUKI Super Grease A) 

   Special Tool 

   (A): 09951-46010 

   Fig 2: Identifying Oil Seal And Front Extension Case

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3. Install intermediate shaft with bearings to front extension case.
4. 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 

      (A): 09913-75520 

      Fig 3: Installing Needle Bearing

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   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 99000-25011 (SUZUKI Super Grease A) 

      Special Tool 

      (A): 09913-75510 

      Fig 4: Installing Oil Seal

      Courtesy of SUZUKI OF AMERICA CORP.
5. 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 99000-31260 (SUZUKI Bond No. 1217G) 

   Tightening torque 

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

   Fig 5: Identifying Sealant On Front Extension Case And Rear Extension Case

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install damper (1) to rear extension case (2) and tighten damper bolts (3) to specified torque.

   Tightening torque 

   Damper bolts (a): 50 N.m (5.0 kg-m, 36.5 lbf-ft) 

   Fig 6: Identifying Damper, Rear Extension Case And Damper Bolts

   Courtesy of SUZUKI OF AMERICA CORP.