Left Case Disassembly and Reassembly: Reassembly

1. Keep pushing outer race with the power of 35 N (3.67 kgf, 7.87 lbf) and turn countershaft assembly and differential case 10 times or more.
2. Measure distance "a" of countershaft assembly (1) and "e" of differential assembly (2).
3. Measure depth "b" and "g" of left case (3) and "c" and "f" of right case (4).
4. Calculate the clearance of "d" and "h" by the following expressions.
   CLEARANCE REFERENCE CHART
   
   

   Clearance of "d" = Depth "b" + Depth "c" - Distance "a"

   CLEARANCE REFERENCE CHART
   
   

   Clearance of "h" = Depth "f" + Depth "g" - Distance "e"

   Fig 2: Identifying Countershaft Left Side Bearing Shim And Differential Left Side Bearing Shim Positions

   Courtesy of SUZUKI OF AMERICA CORP.
5. Select shims closest to clearance "d" and "h" from among the following available sizes.

   Available shim thickness 

   SHIM THICKNESS SPECIFICATIONS
   
   

   Clearance "d"	Select shim
   0.795 - 0.845 mm (0.0313 - 0.332 in.)	1.00 mm (0.0394 in.)
   0.845 - 0.895 mm (0.0332 - 0.0352 in.)	1.05 mm (0.0413 in.)
   0.895 - 0.945 mm (0.0352 - 0.0372 in.)	1.10 mm (0.0433 in.)
   0.945 - 0.995 mm (0.0372 - 0.0391 in.)	1.15 mm (0.0453 in.)
   0.995 - 1.045 mm (0.0391 - 0.0411 in.)	1.20 mm (0.0472 in.)
   1.045 - 1.095 mm (0.0411 - 0.0431 in.)	1.25 mm (0.0492 in.)
   1.095 - 1.145 mm (0.0431 - 0.0450 in.)	1.30 mm (0.0512 in.)
   1.145 - 1.195 mm (0.0450 - 0.0470 in.)	1.35 mm (0.0531 in.)
   1.195 - 1.245 mm (0.0470 - 0.0490 in.)	1.40 mm (0.0551 in.)
   1.245 - 1.295 mm (0.0490 - 0.0509 in.)	1.45 mm (0.0571 in.)
   1.295 - 1.345 mm (0.0509 - 0.0529 in.)	1.50 mm (0.0591 in.)
   1.345 - 1.395 mm (0.0529 - 0.0549 in.)	1.55 mm (0.0610 in.)
   1.395 - 1.445 mm (0.0549 - 0.0568 in.)	1.60 mm (0.0630 in.)
   1.445 - 1.495 mm (0.0568 - 0.0588 in.)	1.65 mm (0.0650 in.)
   1.495 - 1.545 mm (0.0588 - 0.0608 in.)	1.70 mm (0.0669 in.)
   1.545 - 1.595 mm (0.0608 - 0.0627 in.)	1.75 mm (0.0689 in.)
   1.595 - 1.645 mm (0.0627 - 0.0647 in.)	1.80 mm (0.0709 in.)
   1.645 - 1.695 mm (0.0647 - 0.0667 in.)	1.85 mm (0.0728 in.)
   1.695 - 1.745 mm (0.0667 - 0.0687 in.)	1.90 mm (0.0748 in.)
   1.745 - 1.795 mm (0.0687 - 0.0706 in.)	1.95 mm (0.0768 in.)
   1.795 - 1.845 mm (0.0706 - 0.0726 in.)	2.00 mm (0.0787 in.)

   SHIM THICKNESS SPECIFICATIONS
   
   

   Clearance "h"	Select shim
   0.795 - 0.835 mm (0.0313 - 0.0329 in.)	1.00 mm (0.0394 in.)
   0.835 - 0.875 mm (0.0329 - 0.0344 in.)	1.04 mm (0.0409 in.)
   0.875 - 0.915 mm (0.0344 - 0.0360 in.)	1.08 mm (0.0425 in.)
   0.915 - 0.955 mm (0.0360 - 0.0376 in.)	1.12 mm (0.0441 in.)
   0.955 - 0.995 mm (0.0376 - 0.0392 in.)	1.16 mm (0.0457 in.)
   0.995 - 1.035 mm (0.0392 - 0.0407 in.)	1.20 mm (0.0472 in.)
   1.035 - 1.075 mm (0.0407 - 0.0423 in.)	1.24 mm (0.0488 in.)
   1.075 - 1.115 mm (0.0423 - 0.0439 in.)	1.28 mm (0.0504 in.)
   1.115 - 1.155 mm (0.0439 - 0.0455 in.)	1.32 mm (0.0520 in.)
   1.155 - 1.195 mm (0.0455 - 0.0470 in.)	1.36 mm (0.0535 in.)
   1.195 - 1.235 mm (0.0470 - 0.0486 in.)	1.40 mm (0.0551 in.)
   1.235 - 1.275 mm (0.0486 - 0.0502 in.)	1.44 mm (0.0567 in.)
   1.275 - 1.315 mm (0.0502 - 0.0518 in.)	1.48 mm (0.0583 in.)
   1.315 - 1.355 mm (0.0518 - 0.0533 in.)	1.52 mm (0.0598 in.)
   1.355 - 1.395 mm (0.0533 - 0.0549 in.)	1.56 mm (0.0614 in.)
   1.395 - 1.435 mm (0.0549 - 0.0565 in.)	1.60 mm (0.0630 in.)
   1.435 - 1.475 mm (0.0565 - 0.0581 in.)	1.64 mm (0.0646 in.)
   1.475 - 1.515 mm (0.0581 - 0.0596 in.)	1.68 mm (0.0661 in.)

Special Tool 

1. 09913-85210 
   Fig 3: Identifying Special Tools For Countershaft Right Bearing Outer Race

   Courtesy of SUZUKI OF AMERICA CORP.

Special Tool 

1. 09924-74510 
2. 09944-66010 
   Fig 4: Identifying Special Tools For Differential Side Bearing Outer Race

   Courtesy of SUZUKI OF AMERICA CORP.