3B
Rear Differential Reassembly
Reference: Rear Differential Dismounting and Remounting:Rear
Reference: Rear Differential Disassembly:Rear
Reference: Rear Differential Inspection:Rear
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.
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.
Drive Bevel Pinion Bearing Outer Race
CAUTION:
Perform press-fitting carefully so as not to tilt outer race.
Install bevel pinion bearing outer races using special tools and hydraulic press.
Special Tool
(A) : 09924–74510
(B) : 09926–68310
(C) : 09913–75510
1. Differential carrier
Differential Case Assembly
1) Install differential side gears, pinions, thrust washers and pinion shafts in differential case.
2) To check thrust play of differential side gear fasten together two case halves by tightening securing bolts to prescribed torque. By comparing thrust play reading, taken as shown in the figure, against thrust play indicated below, increase or decrease total thickness of thrust washers, which are located in two places, that is, on the inner side of each case half.
Special Tool
(A) : 09930–40113
Tightening torque
Differential case bolt ( a ): 41 N·m ( 4.1 kg-m, 30.0 lb-ft)
Differential side gear thrust play
Standard: 0.12 – 0.37 mm (0.005 – 0.014 in.)
Available differential gear thrust washer thickness
0.6, 0.7 and 0.8 mm (0.024, 0.028 and 0.032 in.)
3) Remove differential case bolts again.
4) Apply thread lock cement to differential case bolts.
“A” : Thread lock cement 99000–32110 ( Thread Lock Cement Super 1322 )
5) Retighten differential case bolts to specified torque.
Tightening torque
Differential case bolt ( a ): 41 N·m ( 4.1 kg-m, 30.0 lb-ft)
6) Put drive bevel gear (1) on differential case (2) and fasten them with 10 bolts (3) by tightening them to specified torque. Use thread lock cement for 10 bolts.
CAUTION:
Use specified bolts. Use of any other bolts than specified may cause loosening of bolts and damage to drive bevel gear.
“A” : Thread lock cement 99000–32110 ( Thread Lock Cement Super 1322 )
Tightening torque
Drive bevel gear bolt ( a ): 85 N·m ( 8.5 kg-m, 61.5 lb-ft)
7) Press-fit differential side bearing (1) with special tool and hydraulic press.
Special Tool
(A) : 09944–66020
8) Hold bearing press-fitted in previous step with holder and press-fit differential side bearing on the other side.
NOTE:
Be sure to use bearing holder for the purpose of protecting lower bearing.
Special Tool
(A) : 09944–66020
(B) : 09951–16060
Differential Carrier and Drive Bevel Pinion
To engage drive bevel pinion and gear correctly, it is prerequired to install drive bevel pinion to differential carrier properly by using adjusting shim.
Special Tool
(A) : 09922–76120
(B) : 09922–76240
(C) : 09922–76550
(D) : 09922–76140
(E) : 09922–76410
(F) : 09922–76310
(G) : 09922–76340
(H) : 09922–76320
(I) : 09922–76150
A: Dummy height of pinion form dummy (= 40 mm/1.575 in.) F: Shim thickness for mounting distance adjustment (= D) 6. Front bearing
B: Radius of bearing form dummy with dummy shaft (= 40 mm/1.575 in.) 1. Pinion form dummy 7. Differential carrier
C: Block dummy thickness (= 14 mm/0.5512 in.) 2. Bearing form dummy with dummy shaft 8. Rear bearing
A+B+C: Mounting distance adjusting dummy total size (= 94 mm/3.701 in.) 3. Block dummy 9. Spacer
D: Measured dimension 4. Dial gauge 10. Drive bevel pinion
E: Drive bevel pinion mounting distance (= 94 mm/1.575 in.) 5. Drive bevel gear      
1) Assemble bearing form dummy with dummy shaft using special tools.
Special Tool
(A) : 09922–76120
(B) : 09922–76240
2) Install dial gauge (1) to bearing form dummy with dummy shaft as shown in the figure.
Dial gauge rod tip set distance
“C”: 2 – 3 mm (0.079 – 0.118 in.)
NOTE:
This installation requires no spacer or oil seal.
3) Apply differential oil to drive bevel pinion front and rear bearings.
4) Install pinion form dummy (1), the other special tools and drive bevel pinion bearings to differential carrier (2).
Special Tool
(A) : 09922–76140
(B) : 09922–76410
(C) : 09922–76310
(D) : 09922–76340
(E) : 09922–76320
(F) : 09922–76150
5) Tighten special tool (1) so that specified bearing preload is obtained.
NOTE:
Before taking measurement, check for rotation by hand more than 15 revolutions.
Special Tool
(A) : 09900–23107
(B) : 09915–24550
(C) : 09922–76150
Drive bevel pinion bearing preload at 50 rpm
0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)
6) Set dial gauge to bearing form dummy with dummy shaft and make 0 (zero) adjustment on surface plate.
NOTE:
• When setting dial gauge to bearing form dummy with dummy shaft, tighten screw lightly. Be careful not to overtighten it, which 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 that short pointer indicates beyond 2 mm when long one is at 0 (zero).
7) Put block dummy (3) on pinion form dummy (2).
Special Tool
(A) : 09922–76550
NOTE:
• Repeat turning back and forth of dummy and measure distance as far as top surface of block 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.
8) Place zero-adjusted bearing form dummy with dummy shaft (1) and dial gauge set on block dummy (3) and take measurement between 0 (zero) position and extended dial gauge measuring tip.
9) Obtain adjusting shim thickness by using measured value by dial gauge in the following equation.
Necessary shim thickness = Dial gauge measured value D
10) Select adjusting shim(s) (2) closest to measured value from among following available sizes.
11) Put shim(s) in place and press-fit drive bevel pinion rear bearing (1) to drive bevel pinion (3) by using special tools and hydraulic press.
Special Tool
(A) : 09924–07730
(B) : 09926–37610–003
Available shim thickness
0.30, 1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21, 1.24, 1.27, and 1.30 mm (0.012, 0.039, 0.041, 0.042, 0.043, 0.044, 0.045, 0.046, 0.048, 0.049, 0.050 and 0.051 in.)
12) Apply differential oil to drive bevel pinion front bearing (1).
13) Install drive bevel pinion front bearing in differential carrier.
14) Apply grease to oil seal lip.
Grease 99000–25010 ( SUZUKI Super Grease A )
15) Install oil seal in differential carrier by using special tool.
Special Tool
(A) : 09944–66010
(B) : 09924–74510
16) Apply differential oil to drive bevel pinion rear bearing (2).
CAUTION:
• Use new drive bevel pinion spacer, otherwise bearings may be damaged.
• Take care not to give press force to drive bevel pinion spacer, otherwise spacer and bearings may be damaged.
17) Install drive bevel pinion (1), spacer (3) and companion flange (5) into differential carrier (4).
18) Until bearing axial clearance come to 1 – 2 mm (0.039 – 0.079 in.), press-fit drive bevel pinion (1) to companion flange (5) by using special tools and hydraulic press.
NOTE:
Bearing axial clearance can be confirmed by shaking differential carrier (4) in the direction shown in the figure.
Special Tool
(A) : 09925–58210
(B) : 09951–46010
19) Tighten flange nut gradually with special tools so that preload of drive bevel pinion is in specification.
NOTE:
• Before taking measurement, check for smooth rotation by hand.
• Preload of drive bevel pinion bearings is adjusted by tightening flange nut to deform drive bevel pinion spacer.
Therefore, be sure to use a new spacer for adjustment and tighten flange nut step by step and check for preload by measuring starting torque as often as tightening to prevent over crushing of spacer.
If preload exceeds specification given below during adjustment, replace spacer and repeat preload adjustment procedure.
Attempt to decrease preload by loosening flange nut will not do.
• For measuring preload of drive bevel pinion bearings, turn drive bevel pinion at about 50 rpm is required.
• Make a record preload of drive bevel pinion bearings because the preload is used for checking composite preload of drive bevel pinion bearings and differential side bearings.
Tightening torque
Flange nut : 100 – 400 N·m ( 10 – 40 kg-m, 72 – 289 lb-ft)
Preload of drive bevel pinion bearings / Starting torque of drive bevel pinion when measuring by torque wrench
0.9 – 1.7 N·m (9.0 – 17.0 kg-cm, 7.8 – 14.7 lb-in.)
Preload of drive bevel pinion bearings / Starting torque of drive bevel pinion when measuring by spring balance
18 – 34 N (1.8 – 3.4 kg, 4.0 – 7.5 lb)
Special Tool
(A) : 09900–23107
(B) : 09915–24550
(C) : 09922–75222
(D) : 09922–66020
1. Power wrench (4 – 10 magnification) 3. Spring balance
2. Socket wrench      
Differential Assembly
1) Place differential side bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
2) Install differential case assembly in differential carrier.
3) Install differential side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.
NOTE:
Screw in each adjuster till it contacts bearing outer race so that outer race is prevented from including.
4) Align match marks (1) on differential side bearing cap and carrier. Screw in two side bearing cap bolts two or three turns and press down bearing cap by hand.
NOTE:
If bearing cap does not fit tightly on carrier, side bearing adjuster is not threaded properly. Reinstall adjuster.
5) Tighten bearing cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque) ( a ): 15 N·m ( 1.5 kg-m, 11.0 lb-ft)
6) Tighten both differential side bearing adjusters (2) so as to obtain specified gear backlash and at the same time, obtain preload of differential side bearing.
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.
• As a practical measure following would be recommended to obtain specified backlash and differential side bearing preload at the same time.
— To increase or decrease backlash for adjustment, displace drive bevel gear toward or away from drive bevel pinion by running in one adjuster and running out the other adjuster by equal amount.
— Tighten both adjusters further by one notch at a time.
Bevel gear backlash
0.10 – 0.20 mm (0.0039 – 0.0078 in.)
Special Tool
(A) : 09930–40120
(B) : 09930–40113
(C) : 09900–20607
(D) : 09900–20701
7) Measure composite preload of drive bevel pinion bearings and differential side bearings with torque wrench (2) or spring balance (1).
8) Calculate preload of differential side bearings by using the following equation.
Preload of differential side bearings = Composite preload – Preload of drive bevel pinion bearings
If preload of differential side bearings is specification shown below, adjust preload by tightening or loosening side bearing adjusters.
Preload of differential side bearings / Starting torque of drive pinion when measuring by torque wrench
0.2 – 0.3 N·m (2.0 – 3.0 kg-cm, 1.7 – 2.6 lb-in.)
Preload of differential side bearings / Starting torque of drive pinion when measuring by spring balance
4.0 – 6.0 N (0.4 – 0.6 kg, 0.9 – 1.3 lb)
Special Tool
(A) : 09900–23107
(B) : 09915–24550
(C) : 09922–75222
3. Companion flange 4. Socket
9) Torque bearing cap bolts to specified torque and install bearing lock plates.
Tightening torque
Bearing cap bolt ( a ): 85 N·m ( 8.5 kg-m, 61.5 lb-ft)
Lock plate bolt ( b ): 11.5 N·m ( 1.15 kg-m, 8.5 lb-ft)
10) As final step, check gear tooth contact as follows.
CAUTION:
When applying red lead paste to teeth, be sure to paint tooth surfaces uniformly. The paste must not be too dry or too fluid.
a) After cleaning tooth surface of about 10 teeth in [A] range, paint them with gear marking compound evenly by using brush (1) or sponge etc.
NOTE:
Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.
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 following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.
A: Paint gear marking compound evenly
11) Upon completion of gear tooth contact check, caulk flange nut (2) with caulking tool (1) and hammer.
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 driver 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.
 
 		 These contact patterns indicate that the “offset” of differential carrier is too much or too little. The remedy is to replace the carrier with a new one.
 		 These contact patterns, located on toe or heel on both drive and coast sides, mean that 1) both pinion and gear are defective, 2) carrier is not true and square, or 3) gear is not properly seated on differential case. The remedy is to replace the defective member.
 		 Irregular patterns: If the pattern is not oval, it means that bevel gear is defective. High or low spots on tooth surfaces or on the seat of bevel gear are the cause of irregular patterns appearing on some teeth. The remedy is to replace the pinion and gear set and, if the seat is defective, so is differential case.