Front 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

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

Fig 1: Identifying Special Tools On Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
After applying differential oil to differential gear (1), pinions (2), pinion shaft (6), pinion washers (3), shims (5), install them in differential case (4).

Fig 2: Identifying Differential Gear, Pinions, Pinion Shaft, Pinion Washers And Shims
Courtesy of SUZUKI OF AMERICA CORP.
Check differential pinion gear (1) for smooth rotation.

Fig 3: Checking Differential Pinion Gear
Courtesy of SUZUKI OF AMERICA CORP.
Align holes of pinion shaft (2) and differential case (3) and drive in new spring pin (1) till they are flush with end surface of case.
Special Tool

(A): 09922-85811

Fig 4: Aligning Of Pinion Shaft And Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).
NOTE: Using bolts other than the specified bolts may cause problems with the front differential.
Use only the specified bolts.

(A): Thread lock cement 99000-32100 (Thread Lock Cement 1305)

Tightening torque

Bevel gear bolt (a): 200 N.m (20.0 kgf-m, 145.0 lbf-ft)

Fig 5: Putting Drive Bevel Gear On Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Install special tool to differential case assembly (1) and check that preload is within specification. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special Tool

(B): 09928-06010-002

Side gear preload

Max. 2.5 N.m (0.25 kgf-m, 1.8 lbf-ft)

Fig 6: Checking Side Gear Preload
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit left side bearing (1) with special tools and hydraulic press.
Special Tool

(A): 09913-75821

(B): 09924-84510-004

Fig 7: Press-Fitting Left Side Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit right side bearing (1) with special tools and hydraulic press.
NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.

Special Tool

(A): 09913-75821

(B): 09924-84510-004

(C): 09924-84510-005

Fig 8: Press-Fitting Right Side Bearing With Special Tools And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Special Tool

(A): 09900-20607

(B): 09926-78320

(C): 09951-16070

(D): 09951-46010

(E): 09926-78311-002

(F): 09922-76520

Fig 9: Identifying Position Of Drive Bevel Pinion, Differential Carrier And Mounting Dummy
Courtesy of SUZUKI OF AMERICA CORP.
Apply differential oil to drive bevel pinion bearings, install special tools with bearings (3) and flange (2) to differential carrier (1).
NOTE: This installation requires no spacer or oil seal.

Special Tool

(E): 09951-46010

(F): 09926-78311-002

Fig 10: Identifying Flange, Bearings, Differential Carrier And Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
Tighten flange nut so that specified bearing preload is obtained.
NOTE:
- Before taking measurement with torque wrench (1), check for rotation by hand and apply small amount of differential oil to bearings.
- On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
Drive bevel pinion bearing preload

0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)

Fig 11: Tightening Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.
Set dial gauge to mounting dummy and make 0 (zero) adjustment on surface plate (1).
NOTE:
- When setting dial gauge to mounting dummy, tighten screw (2) lightly. Be careful not to overtighten it, which will cause damage to dial gauge.
- With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.
- It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).
Special Tool

(A): 09900-20607

(B): 09926-78320

Fig 12: Tightening Screw
Courtesy of SUZUKI OF AMERICA CORP.
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.
Special Tool

(A): 09900-20607

(B): 09926-78311

(D): 09951-16070

(F): 09926-78311-002

: 09922-76520

Fig 13: Identifying Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
Obtain adjusting shim thickness by the following equation.
Necessary shim thickness "e" = Mounting dummy size 103.0 mm/4.0551 in. "a" + "b" + Measured dimension "c" - Drive bevel pinion mounting distance 102 mm/4.0157 in.
Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit rear bearing (1).
Special Tool

(G): 09913-85210

(H): 09940-53111

Available drive bevel pinion adjusting shim thickness

1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 and 0.3 mm (0.039, 0.040, 0.042, 0.043, 0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)

Fig 14: Identifying Drive Bevel Pinion, Rear Bearing, Adjusting Shim And Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
With new pinion spacer (3) inserted as shown in figure, apply differential oil to bearings and then install front bearing (5) to differential carrier (4).
NOTE: Make sure to use new spacer for reinstallation.

Fig 15: Identifying Drive Bevel Pinion, Pinion Spacer, Front Bearing And Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1). Then apply grease "A" to oil seal lip.
"A": Grease 99000-25011 (SUZUKI Super Grease A)

Special Tool

(A): 09944-66010

(B): 09924-74510

Fig 16: Driving Oil Seal Into Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to both sides of bevel pinion washer. Refer to Front Differential Components .
: Grease 99000-25011 (SUZUKI Super Grease A)
Apply grease to front bearing contact face of universal joint flange. Refer to Front Differential Components .
: Grease 99000-25011 (SUZUKI Super Grease A)
While tightening flange nut gradually with special tool and power wrench (4 - 10 magnification) (1), set preload of pinion to specification.
NOTE:
- Before taking measurement with torque wrench (3), check for smooth rotation by hand.
- On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
- Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.
Drive bevel pinion bearing preload

0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)

Special Tool

(A): 09922-66021

Fig 17: Tightening Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.
Select differential side bearing shim as follows.
1. Measure dimension "a" and "b" using vernier caliper.
  
  Fig 18: Identifying Differential Side Bearing Shim Dimensions
  Courtesy of SUZUKI OF AMERICA CORP.
2. Calculate dimension "a" - "b", and select shims from among following available size so that total of thickness of right side and left side shims may reach the calculated value.
  NOTE: Select shims so that thickness of right side shims and left side shims become almost even.
  
  Available differential side bearing adjusting shim thickness
  
  Right side: 1.75, 1.85, 1.95, 2.00, 2.05, 2.15 and 2.25 mm (0.069, 0.073, 0.077, 0.079, 0.081, 0.085 and 0.089 in.)
  
  Left side: 2.75, 2.85, 2.95, 3.00, 3.05, 3.15 and 3.25 mm (0.108, 0.112, 0.116, 0.118, 0.120, 0.124 and 0.128 in.)
To measure bevel gear backlash, set dial gauge (1) at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear.
Special Tool

(A): 09900-20607

(B): 09900-20701

Bevel gear backlash

: 0.1 - 0.2 mm (0.004 - 0.008 in.)
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- Measure at least 4 points on drive bevel gear periphery.
- If backlash exceeds specification given below, adjust it by changing thickness ratio of differential side bearing shims.
Fig 19: Measuring Bevel Gear Backlash
Courtesy of SUZUKI OF AMERICA CORP.
Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
Install case assembly (1) in carrier (2).

Fig 20: Installing Case Assembly In Carrier
Courtesy of SUZUKI OF AMERICA CORP.

As final step, check gear tooth contact as follows.

After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact.

Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table.

NOTE: Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

Fig 21: Inspecting Gear Tooth Contact

Courtesy of SUZUKI OF AMERICA CORP.

Tooth Contact Pattern	Diagnosis and Remedy
	Normal
	High Contact Pinion is positioned too far from the center of drive bevel gear (1). Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. Adjust drive bevel gear backlash to specification.
	Low Contact Pinion is positioned too close to the center of drive bevel gear (1). Decrease thickness of pinion (2) height adjusting shim and position pinion farther from gear center. Adjust drive bevel gear backlash to specification.
	If adjustment is impossible, replace differential carrier.
	Check seating of bevel gear or differential case. (Check bevel gear for runout.) If adjustment is impossible, replace drive bevel gear and pinion set or differential carrier.
	Replace drive bevel gear and pinion set or differential case.

Upon completion of gear tooth contact check in Step 22), caulk flange nut (2) with caulking tool (1) and hammer.

Fig 22: Caulking Flange Nut Using Caulking Tool
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of differential carrier (2) and rear cover (1), apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate rear cover with differential carrier, and then tighten bolts to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)

Tightening torque

Rear cover bolt No. 1 (a): 50 N.m (5.0 kgf-m, 36.5 lbf-ft)

Rear cover bolt No. 2 (b): 60 N.m (6.0 kgf-m, 43.5 lbf-ft)

Fig 23: Identifying Sealant Applying Areas Of Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Assembly front drive shaft retainer as follows.
1. Install front drive shaft bearing (1) using special tool, and then install snap ring.
  Special Tool
  
  (A): 09913-75520
  
  Fig 24: Installing Front Drive Shaft Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
2. Apply grease to oil seal lip, and then install oil seal (1) using special tools as shown in figure.
  Distance between retainer surface and oil seal
  
  "a": 4.7 - 5.2 mm (0.185 - 0.205 in.)
  
  "A": Grease 99000-25011 (SUZUKI Super Grease A)
  
  Special Tool
  
  (A): 09924-74510
  
  (B): 09951-16091
  
  Fig 25: Installing Oil Seal Using Special Tools
  Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to oil seal lip, and then install oil seal (2) into differential side right retainer (1) at specified position as shown in figure.
Distance between retainer surface and oil seal

"a": 0.65 - 1.65 mm (0.026 - 0.065 in.)

"A": Grease 99000-25011 (SUZUKI Super Grease A)

Special Tool

(A): 09924-74510

(B): 09926-27610

Fig 26: Installing Oil Seal Into Differential Side Right Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate right retainer with carrier and rear cover, and then tighten bolts to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)

Tightening torque

Retainer bolt: 50 N.m (5.0 kgf-m, 36.5 lbf-ft)

Fig 27: Identifying Sealant Applying Area Of Carrier And Rear Cover
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of front drive shaft retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate front drive shaft retainer with carrier and rear cover, and then tighten bolts to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)

Tightening torque

Retainer bolt: 50 N.m (5.0 kgf-m, 36.5 lbf-ft)

Fig 28: Identifying Sealant Applying Area Of Carrier And Rear Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install front drive shaft using plastic hammer.
Install front differential rear mounting (2).
Tightening torque

Rear mounting bracket bolt (a): 60 N.m (6.1 kgf-m, 44.5 lbf-ft)

Fig 29: Identifying Front Differential, Rear Mount Bracket And Bracket Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Install front differential right mounting (2).
Tightening torque

Right mounting bracket bolt (b): 50 N.m (5.0 kgf-m, 36.5 lbf-ft)

Fig 30: Identifying Front Differential And Right Mounting Bracket Bolt
Courtesy of SUZUKI OF AMERICA CORP.