Rear Differential Assembly Reassembly
ReassemblyJudging 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.
CAUTION:
^ Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
^ When replacing taper roller bearing, replace as inner race and outer race assembly.
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
2) After applying differential oil to differential gear (4), pinions (5), pinion shafts (6), pinion washer, thrust washer (2) and spring washer (1), install them in differential right case (3). For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.
3) Check differential pinion gear (1) for smooth rotation.
4) 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).
CAUTION:
Use of any other bolts than that specified is prohibited.
"A": Thread lock cement 99000-32110 (Thread Lock Cement Super 1322)
Tightening torque
Bevel gear bolt (a): 200 Nm (20.0 kg-m, 145.0 ft. lb.)
5) Install special tool to differential case assembly (2) and check differential gear for preload. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special Tool
(B):09928-06510
Differential gear preload
Max. 2.5 Nm (0.25 kgf-m, 1.8 lb-ft)
6) Press-fit left side bearing (1) with special tool and hydraulic press.
Special Tool
(A):09913-75821
(B):09924-84510-004
7) 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
8) 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):09922-75222
(D):09951-16070
(E):09951-46010
(F):09926-78311-002
(G):09922-76520
9) 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
10) Tighten flange nut (1) so that specified bearing preload is obtained.
NOTE:
^ Before taking measurement with spring balance (2) or torque wrench (3), 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.
Special Tool
(C):09922-75222
(F):09926-78311-002
Pinion bearing preload
0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)
Spring measure reading with special tool
20 - 40 N (2.0 - 4.0 kg, 4.4 - 8.8 lb)
11) 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
12) 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
13) Obtain adjusting shim thickness by the following equation.
14) 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 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.)
15) With new pinion spacer (3) inserted as shown in the figure, install front bearing (5) to differential carrier (4).
NOTE:
^ Make sure to use new spacer for reinstallation.
^ Apply differential oil to bearings.
16) Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) as shown in figure. Then apply grease "A" to oil seal lip.
"A": Grease 99000-25010 (SUZUKI Super Grease A)
Special Tool
(A):09951-18210
17) 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 spring balance (3) or torque wrench (4), 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.
Pinion bearing preload
0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)
Spring measure reading with special tool
20 - 40 N (2.0 - 4.0 kg, 4.4 - 8.8 lb)
Special Tool
(A):09922-75222
(B):09922-66021
18) Select differential side bearing shim as follows.
a) Measure dimension "a" and "b" using vernier caliper.
b) 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 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.)
19) 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.
20) Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
21) Install case assembly (1) in carrier (2).
22) As final step, check gear tooth contact as follows.
a) After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
b) 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.
c) 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.
23) Upon completion of gear tooth contact check in Step 22), caulk flange nut (2) with caulking tool (1) and hammer.
24) 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 Nm (5.0 kg-m, 17.0 ft. lb.)
Rear cover bolt No.2 (b): 60 Nm (6.0 kg-m, 43.5 ft. lb.)
25) Assembly rear drive right retainer as follows.
a) Install rear drive shaft bearing (1) using special tool and press (2).
Special Tool
(A):09913-75520
b) Install snap ring.
c) Install oil seal using special tools as shown in figure.
Distance between retainer surface and oil seal
"a": 2.5 - 3.0 mm (0.10 - 0.12 in.)
Special Tool
(A):09924-74510
(B):09951-16090
26) Assembly rear drive left retainer in the same manner at Step 25) in this assembly procedure.
27) 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 Nm (5.0 kg-m, 36.5 ft. lb.)
28) Clean mating surface of left 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 left 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 Nm (5.0 kg-m, 36.5 ft. lb.)
29) Install rear drive right and left shaft using plastic hammer.