Rear Differential Disassembly and Reassembly: Reassembly

Special Tool 

1. 09913-85210 
2. 09913-75510 

Fig 1: Pressing Bevel Pinion Bearing Outer Races To Differential Carrier

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1. Apply differential oil to front bearing (2) and rear bearing (1).
2. Install front bearing, rear bearing and special tools (mounting dummy) to differential carrier (3).
   NOTE: Special tools (A) - (D) are included in differential adjuster set (09922-76110).

   Special Tool 

   1. 09922-76140 
   2. 09922-76420 
   3. 09922-76330 
   4. 09922-76340 
   5. 09922-76150 
   6. 09922-76530 
   Fig 2: Sectional View Of Differential

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3. Tighten bevel pinion nut (special tool) so that specified bearing preload is obtained.

   Special Tool 

   1. (A): 09922-76140 
   2. (E): 09922-76150 
   NOTE: Before preload measurement with torque wrench, rotate special tool more than 15 revolutions by hand.

   Bevel pinion bearing preload (special tool rotational torque) 

   : 1.3 - 2.6 N.m (0.13 - 0.27 kgf-m, 1.0 - 2.0 lbf-ft) (rotational speed about 50 rpm) 

   Fig 3: Tightening Bevel Pinion Nut

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4. Set dial gauge to axle dummy and make 0 (zero) adjustment on surface plate (1).
   NOTE:

   • When setting dial gauge to mounting dummy (axle dummy), tighten screw lightly. Be careful not to overtighten it as this will cause damage to dial gauge.
   • With dial gauge set, turn dummy back and forth by hand a couple of times and attain accurate 0 (zero) adjustment.
   • It is desirable to have the short pointer indicate beyond 2 mm when long one is at 0 (zero).
   • Special tools (G) - (H) are included in differential adjuster set (09922-76110).

   Special Tool 

   1. (G): 09922-76250 
   2. (H): 09922-76120 
   3. (I): 09900-20607 
   Fig 4: Setting Dial Gauge To Axle Dummy And Make 0 (Zero) Adjustment On Surface Plate

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5. Place zero-adjusted axle dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip.
   NOTE:

   • Repeat turning back and forth of axle dummy and accurately measure distance as far as top surface of pinion dummy.
   • When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
6. Dimensional relation of each dummy is as follows. Use the dial gauge reading to calculate the thickness of bevel pinion shim "g" with the formula.

   "g" (mm) = "e" - "f"

   "e": "a" + "b" + "c" + "d"

   • "a": measured value (dial gauge reading)
   • "b": special tool (G) radius (31.00 mm (1.220 in.))
   • "c": special tool (A) height (40.00 mm (1.575 in.))
   • "d": special tool (F) height (9.00 mm (0.345 in.))

   "f": bevel pinion mounting distance (80.00 mm (3.150 in.))

   Fig 5: Identifying Bevel Pinion Mounting Distance

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7. Select bevel pinion shim that is closest in thickness to "g" (dial gauge reading) in procedure f).

   Available bevel pinion shim thickness 

   SHIM THICKNESS SPECIFICATION
   
   

   Select shim
   0.30 mm (0.012 in.)
   0.60 mm (0.023 in.)
   0.63 mm (0.024 in.)
   0.66 mm (0.026 in.)
   0.69 mm (0.027 in.)
   0.72 mm (0.028 in.)
   0.75 mm (0.030 in.)
   0.78 mm (0.031 in.)
   0.81 mm (0.032 in.)
   0.84 mm (0.033 in.)
   0.87 mm (0.034 in.)

Special Tool 

1. 09913-85210 
2. 09924-07720 

Fig 6: Installing Selected Shim And Rear Bearing To Bevel Pinion

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

Distance between differential carrier and oil seal 

"a": 0.5 - 1.5 mm (0.02 - 0.06 in.) 

Special Tool 

1. 09913-85210 

Fig 8: Identifying Distance Between Differential Carrier And Oil Seal

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Bevel pinion bearing preload (Bevel pinion rotational torque) 

: 1.3 - 2.6 N.m (0.13 - 0.27 kgf-m, 1.0 - 2.0 lbf-ft) (rotational speed about 50 rpm) 

Special Tool 

1. 09927-27910 

Fig 9: Tightening Bevel Pinion Nut

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Fig 10: Measuring Bevel Pinion Bearing Preload

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Install side washers and spring washers in correct direction, as shown in figure.

Fig 11: Identifying Differential Gears, Pinions, Pinion Shaft And Side Washers

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Special Tool 

1. 09922-85811 

Fig 13: Aligning Holes Of Pinion Shaft And Differential Case

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Differential gear thrust play 

: 0.00 - 0.37 mm (0.0 - 0.01 in.) 

Available side washer thickness 

Special Tool 

1. 09900-20607 
2. 09900-20701 

Fig 14: Measuring Differential Gear Thrust Play

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Tightening torque 

Bevel gear bolt (a): 78 N.m (8.0 kg-m, 57.5 lbf-ft) 

Fig 15: Identifying Bevel Gear And Differential Case

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Special Tool 

1. 09913-80113 
2. 09926-48010 

Fig 16: Pressing Differential Right Side Bearing

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Special Tool 

1. 09913-80113 
2. 09926-48010 
3. 09925-88210 

Fig 17: Pressing Differential Left Side Bearing

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1. Measure bearings (2) (3) distance "a".
   Fig 18: Measuring Bearings Distance "A"

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2. Measure distance "b" of bearing retaining position in differential carrier (1).
   Fig 19: Measuring Distance "B" Of Bearing Retaining Position In Differential Carrier

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3. Calculate dimension for selecting shim.

   Differential side shim thickness (mm (in.)) = "b" - "a"

4. Select a shim (4) which is close to half the thickness of the calculated value (necessary shim thickness) from among the available shims to install it between the bearing and carrier (3) on the right and left sides.

   Available differential side shim thickness 

   DIFFERENTIAL SIDE SHIM THICKNESS SPECIFICATION
   
   

   Select shim
   0.45 mm (0.017 in.)
   2.30 mm (0.090 in.)
   2.35 mm (0.092 in.)
   2.40 mm (0.094 in.)
   2.45 mm (0.096 in.)
   2.50 mm (0.098 in.)
   2.55 mm (0.100 in.)
   2.60 mm (0.102 in.)
   2.65 mm (0.104 in.)
   2.70 mm (0.106 in.)

   Fig 20: Identifying Differential Side Left And Right Bearing

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5. Install differential cover and then tighten differential cover bolts to specified torque.
   CAUTION:

   • Differential cover is also differential side bearing cap. Tighten cover bolts as specified when checking backlash and gear contact.
   • Do not apply sealant yet to mating surface of differential carrier and differential cover when measuring backlash and tooth contact.

   Tightening torque 

   Differential cover bolt: 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

6. Remove differential cover.
7. To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix bevel pinion and read dial gauge while moving bevel gear.

   If bevel gear backlash is out of specification, adjust it by either changing thickness ratio or replacing parts.

   NOTE:

   • Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
   • Measure at least 4 points on bevel gear periphery.

   Bevel gear backlash 

   0.1 - 0.2 mm (0.004 - 0.008 in.) 

   Special Tool 

   1. 09900-20607 
   2. 09900-20701 
   Fig 21: Measuring Bevel Gear Backlash

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8. As final step, check gear tooth contact as follows:
   1. After cleaning 10 bevel gear teeth, paint them with gear marking compound evenly with a brush (1) or sponge etc.
   2. Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact.
   3. Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace if necessary according to instructions in the table.
      NOTE: Be careful not to turn bevel gear more than one full revolution as it will hinder accuracy of check.
      Fig 22: Cleaning Bevel Gear Teeth

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      NOTE: If bevel gear backlash and bevel pinion shims are adjusted properly, correct tooth contact should be provided. However, if correct tooth contact is not provided even when they are adjusted properly, there may be an abnormal condition in tooth, differential case or differential carrier. Check each component and replace if necessary.
      TOOTH CONTACT PATTERN
      
      

      Tooth contact pattern	Diagnosis and remedy
      Courtesy of SUZUKI OF AMERICA CORP.	Normal
      Courtesy of SUZUKI OF AMERICA CORP.	High Contact Pinion is positioned too far from the center of bevel gear (2). Increase thickness of pinion (1) height adjusting shim and position pinion closer to gear center. Adjust bevel gear backlash to specification.
      Courtesy of SUZUKI OF AMERICA CORP.	Low Contact Pinion is positioned too close to the center of bevel gear (2). Decrease thickness of pinion (1) height adjusting shim and position pinion farther from gear center. Adjust bevel gear backlash to specification.
      Courtesy of SUZUKI OF AMERICA CORP.	Replace differential carrier if adjustment is impossible.
      Courtesy of SUZUKI OF AMERICA CORP.	Check seating of bevel gear or differential case. (Check bevel gear for runout.) Replace bevel gear and pinion set or differential carrier if adjustment is impossible.
      Courtesy of SUZUKI OF AMERICA CORP.	Replace bevel gear and pinion set or differential case.

9. Install differential cover and then tighten differential cover bolts to specified torque.
   CAUTION:

   • Differential cover is also differential side bearing cap. Tighten cover bolts as specified when checking backlash and gear contact.
   • Do not apply sealant yet to mating surface of differential carrier and differential cover when measuring backlash and tooth contact. Do not apply sealant yet to mating surface of differential carrier and differential cover.

   Tightening torque 

   Differential cover bolt: 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

Bevel pinion bearing preload (Bevel pinion rotational torque) 

: Preload measured in Step   8 ) +0.3 - 0.7 N.m (3 - 7 kgf-cm, 2.6 - 6.0 lb-in.) (rotational speed about 50 rpm) 

Fig 23: Measuring Bevel Pinion Bearing Preload

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"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) 

Tightening torque 

Differential cover bolt: 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

Fig 24: Identifying Sealant Applying Area

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Special Tool 

1. 09913-75810 

Fig 25: Pressing Bearing

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

Distance between case and oil seal "a" 

: 1.5 - 2.5 mm (0.06 - 0.10 in.) 

Special Tool 

1. 09913-75810 

Fig 27: Identifying Distance Between Case And Oil Seal

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"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) 

Special Tool 

1. 09913-70123 

Fig 29: Installing Grommet Of Coupling Harness Into Groove Of Coupling Case

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Tightening torque 

Flange nut: 110 N.m (11.2 kg-m, 81.5 lbf-ft) 

Special Tool 

1. 09930-40113 

Fig 30: Holding Companion Flange With Special Tool

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Companion flange inside diameter runout limit 

: 0.1 mm (0.004 in.) 

Special Tool 

1. 09952-06010 
2. 09900-20607 
3. 09900-20701 

Fig 31: Measuring Runout Of Companion Flange

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"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) 

Tightening torque 

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

Fig 32: Cleaning Mating Surface Of Differential Carrier

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Fig 33: Identifying Differential Carrier Bolts

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

Distance between rear differential and oil seal "a" 

: 0.0 - 1.0 mm (0.00 - 0.04 in.) 

Special Tool 

1. 09922-59420 

Fig 34: Identifying Distance Between Rear Differential And Oil Seal

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