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Service Manual Update: Rear Differential Special Tools (TS 10 12102)

Publication date: 2012-12-14
Reference number: TS 10 12102

SERVICE MANUAL UPDATE: REAR DIFFERENTIAL SPECIAL TOOLS

SERVICE MANUAL UPDATE: REAR DIFFERENTIAL SPECIAL TOOLS

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 10 12102, Date of Issue:  December 14, 2012
SUZUKI: 2006~2013 GRAND VITARA (JB424, JB627, JB632)
SECTION: Driveline-Axle-Differential

CONDITION

This bulletin is being provided to inform you of service manual corrections for the special tool, Differential Bevel Pinion Dummy. These corrections apply to the rear differential service information described in the service manual Section 3B for 'Rear Differential Assembly Disassembly and Reassembly' and 'Special Tool' found within 2006~2013 Grand Vitara (JB424/JB627/JB632) Service Manuals.

CORRECTION

Please refer to changes illustrated in the attached pages of this bulletin that have been made to service manual section(s) applying to the 2006~2013 Grand Vitara (JB424/JB627/JB632) Service Manuals. The following table describes the Service Manual(s) and the corresponding section(s) that have been added/amended. The Online Service Manual has been revised prior to the release of this bulletin.

AFFECTED SERVICE MANUAL(S)

AFFECTED SERVICE MANUALS

Manual Name Part Number Corresponding Item
2006 GRAND VITARA (JB627) Service Manual 99500S66J00-33E Section 3B: 
  • Rear Differential Assembly Disassembly and Reassembly
  • Special Tool
2007 GRAND VITARA (JB627) Service Manual 99500S66J10-33E
2008 GRAND VITARA (JB627) Service Manual 99500-66J20-33E
2009 GRAND VITARA (JB424/JB632) Service Manual 99500-66J30-33E
2010 GRAND VITARA (JB424/JB632) Service Manual 99500-66J40-33E
2011 GRAND VITARA (JB424) Service Manual 99500-66J50-33E
2012 GRAND VITARA (JB424) Service Manual 99500-66J60-33E
2013 GRAND VITARA (JB424) Service Manual 99500-66J70-33E

Please refer to changes illustrated in the following pages. 

REAR DIFFERENTIAL ASSEMBLY DISASSEMBLY AND REASSEMBLY

Reassembly

Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described.

NOTE: Some parts are intended to be replaced as a set. If you replace these parts individually, rather than as a set, performance may be adversely affected.
Always replace the following parts as a set or in an assembly.
  • Bevel gear and pinion
  • Inner and outer races of a taper roller bearing
  1. For press-fitting drive bevel pinion bearing outer races, use special tools and press as shown in the figure.

    Special Tool 

    (A): 09924-74510 

    (B): 09925-14520 

    (C): 09913-75510 

    G08610771
  2. Place zero-adjusted mounting dummy and dial gauge set on pinion mounting dummy and take measurement between zero position and extended dial gauge measuring tip.
    NOTE:
    • Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurately.
    • When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
    • Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.
    G08610772

ATTACHED SHEET 2/10 

2006 JB627 (99500S66J00-33E) 

2007 JB627 (99500S66J10-33E) 

2008 JB627 (99500-66J20-33E) 

Differential: Rear 3B 

SPECIAL TOOL

SPECIAL TOOL

09900-20607
Dial gauge
(L3B273)/(L3B284)/(L3B286)/(L3B296)
G08610773
 09900-20701
Magnetic stand
(L3B297)
G08610774
09913-50121
Oil seal remover
(L3B255)/(L3B263)
G08610775
 09913-65135
Bearing puller
(L3B258)/(L3B261
G08610776
09913-75510
Bearing installer
(L3B266)
G08610777
 09913-75520
Bearing installer
(L3B298
G08610778
09913-75821
Bearing installer attachment
(L3B268)/(L3B270)
G08610779
 09913-85210
Bearing installer
(L3B291)
G08610780
09914-95410
Mounting remover set
(L3B249)/(L3B250)/l251)/(L3B252)
G08610781
 09922-66021
Flange holder
(L3B260)/(L3B295)
G08610782
09922-75222
Differential gear preload adjuster
(L3B275)/(L3B282)/(L3B294)
G08610783
 09922-76520
Bevel pinion gauge block
(L3B279)/(L3B290)
G08610784
09924-74510
Bearing and oil seal handle
(L3B264)/(L3B299)
G08610785
 09924-84510-004
Bearing installer attachment
(L3B269)/(L3B271)
G08610786
09924-84510-005
Bearing installer attachment (D)
(L3B272)
G08610787
 09925-14520
Bearing and oil sear installer (80 x 50 mm)
(L3B265)
G08610788
09925-86010
Bearing puller attachment
(L3B259)
G08610789
 09925-88210
Bearing puller attachment
(L3B262)
G08610790
09926-78311-002
Pinion mounting dummy
This tool is included in differential bevel pinion dummy set (09926-78311)/(L3B278)/(L3B281)/(L3B283)/(L3B289)
G08610791
 09926-78320
Mounting dummy
(L3B274)/(L3B285)/(L3B287)
G08610792
09928-06510
Differential torque checking tool
(L3B267)
G08610793
 09930-30104
Sliding shaft
(L3B256
G08610794
09940-53111
Differential side bearing installer
(L3B292)
G08610795
 09941-64511
Bearing and oil seal remover (30 mm min.)
(L3B257)
G08610796
09942-15511
Sliding hammer
(L3B253)
G08610797
 09943-17912
Wheel hub remover
(L3B254)
G08610798
09951-16070
Shim adjuster attachment
(L3B276)/(L3B288)
G08610799
 09951-16090
Oil seal installer
(L3B2100)
G08610800
09951-18210
Oil seal remover & installer No. 2
(L3B293)
G08610801
 09951-46010
Drive shaft oil seal installer
(L3B277)/(L3B280)
G08610802

ATTACHED SHEET 5/10 

2009 JB424/JB632 (99500-66J30-33E) 

2010 JB424/JB632 (99500-66J40-33E) 

2011 JB424 (99500-66J50-33E) 

Differential: Rear 3B 

SPECIAL TOOL

09900-20607
Dial gauge
(L3B272)/(L3B280)/(L3B282)/(L3B291)
G08610803
 09900-20701
Magnetic stand
(L3B292)
G08610804
09913-50121
Oil seal remover
(L3B253)/(L3B256)/(L3B262)
G08610805
 09913-65135
Bearing puller
(L3B257)/(L3B260)
G08610806
09913-75510
Bearing installer
(L3B265)
G08610807
 09913-75520
Bearing installer
(L3B293)/(L3B296)
G08610808
09913-75821
Bearing installer attachment
(L3B267)/(L3B269)
G08610809
 09913-85210
Bearing installer
(L3B287)
G08610810
09914-95410
Mounting remover set
(L3B247)/(L3B248)/(L3B249)/(L3B250)
G08610811
 09922-76520
Bevel pinion gauge block
(L3B277)/(L3B286)
G08610812
09924-74510
Bearing and oil seal handle
(L3B263)/(L3B294)
G08610813
 09924-84510-004
Bearing installer attachment
(L3B268)/(L3B270)
G08610814
09924-84510-005
Bearing installer attachment (D)
(L3B271)
G08610815
 09925-14520
Bearing and oil seal installer (80 x 50 mm)
(L3B264)
G08610816
09925-86010
Bearing puller attachment
(L3B258)
G08610817
 09925-88210
Bearing puller attachment
(L3B261)
G08610818
09926-78311-002
Pinion mounting dummy
This tool is included in differential bevel pinion dummy set (09926-78311)/(L3B276)/(L3B279)/(L3B285)
G08610819
 09926-78320
Mounting dummy
(L3B273)/(L3B281)/(L3B283)
G08610820
09928-06510
Differential torque checking tool
(L3B266)
G08610821
 09930-30104
Sliding shaft
(L3B254)
G08610822
09930-40113
Flywheel rotor holder
(L3B259)/(L3B290)
G08610823
 09940-53111
Differential side bearing installer
(L3B288)
G08610824
09941-64511
Bearing and oil seal remover (30 mm min.)
(L3B255)
G08610825
 09942-15511
Sliding hammer
(L3B251)
G08610826
09943-17912
Wheel hub remover
(L3B252)
G08610827
 09951-16070
Shim adjuster attachment
(L3B274)/(L3B284)
G08610828
09951-16091
Oil seal installer
(L3B295)
G08610829
 09951-18211
Oil seal remover & installer No. 2
(L3B289)
G08610830
09951-46010
Drive shaft oil seal installer
(L3B275)/(L3B278)
G08610831
  

ATTACHED SHEET 8/10 

2012 JB424 (99500-66J60-33E) 

2013 JB424 (99500-66J70-33E) 

Differential: Rear 3B 

SPECIAL TOOL

09900-20607
Dial gauge
(L3B274)/(L3B282)/(L3B284)/(L3B293)
G08610832
 09900-20701
Magnetic stand
(L3B294)
G08610833
09913-50121
Oil seal remover
(L3B255)/(L3B258)/(L3B264)
G08610834
 09913-65135
Bearing puller
(L3B259)/(L3B262)
G08610835
09913-75510
Bearing installer
(L3B267)
G08610836
 09913-75520
Bearing installer
(L3B295)
G08610837
09913-75821
Bearing installer attachment
(L3B269)/(L3B271)
G08610838
 09913-85210
Bearing installer
(L3B289)
G08610839
09914-95410
Mounting remover set
(L3B249)/(L3B250)/(L3B251)/(L3B252)
G08610840
 09922-76520
Bevel pinion gauge block
(L3B279)/(L3B288)
G08610841
09924-74510
Bearing and oil seal handle
(L3B265)/(L3B296)/(L3B298)
G08610842
 09924-84510-004
Bearing installer attachment
(L3B270)/(L3B272)
G08610843
09924-84510-005
Bearing installer attachment (D)
(L3B273)
G08610844
 09925-14520
Bearing and oil seal installer (80 x 50 mm)
(L3B266)
G08610845
09925-86010
Bearing puller attachment
(L3B260)
G08610846
 09925-88210
Bearing puller attachment
(L3B263)
G08610847
09926-27610
Oil seal installer
(L3B299)
G08610848
 09926-778311-002
Pinion mounting dummy
This tool is included in differential bevel pinion dummy set (09926-78311)/(L3B278)/(L3B281)/(L3B287)
G08610849
09926-78320
Mounting dummy
(L3B275)/(L3B283)/(L3B285)
G08610850
 09928-06510
Differential torque checking tool
(L3B268)
G08610851
09930-30104
Sliding shaft
(L3B256)
G08610852
 09930-40113
Flywheel rotor holder
(L3B261)/(L3B292)
G08610853
09940-53111
Differential side bearing installer
(L3B290)
G08610854
 09941-64511
Bearing and oil seal remover (30 mm min.)
(L3B257)
G08610855
09942-15511
Sliding hammer
(L3B253)
G08610856
 09943-17912
Wheel hub remover
(L3B254)
G08610857
09951-16070
Shim adjuster attachment
(L3B276)/(L3B286)
G08610858
 09951-16091
Oil seal installer
(L3B297)
G08610859
09951-18211
Oil seal remover & installer No. 2
(L3B291)
G08610860
 09951-46010
Drive shaft oil seal installer
(L3B277)/(L3B280)
G08610861
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