Front & Rear (M41 & M59) Differential Assemblies: Reassembly

Install right side gear and washer, differential pinion gears and washers, cross shafts and pinion cross shaft joint into right differential case. Measure right side differential side gear end play using Dial Indicator (J-8001). Insert fingers through bottom opening of right differential case half and move right differential side gear up and down while observing dial indicator. The right differential side gear end play should measure .005-.014" (.12-.36 mm). SeeFig 1 . Replace selective shim with appropriate size. SeeFig 2 . Install cross shaft roll pins into right differential case half. Roll pin ends should be flush with right differential case surface.

Fig 1: Measuring Right Side Gear End Play
Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Identifying Side Gear Selective Shim
Courtesy of SUZUKI OF AMERICA CORP.
Install left differential side gear and washer into right differential case. Install left differential case half and ring gear onto right differential case half. Measure left differential side gear end play using dial indicator and Side Gear Thrust Play Gauge (J-35138). Insert thrust play gauge through left axle shaft differential case bore, and adjust until it is firmly attached onto side gear. Move side gear thrust gauge up and down while observing the dial indicator. Left differential side gear end play should measure .005-0.014" (.12-.35 mm) Fig 3 .
Install side gear preload onto left differential case using Differential Torque gauge (J-8890) with a torque wrench. The maximum side gear preload 21 INCH lbs. (2.4 N.m). Install right differential side bearing onto right side of differential case assembly using Pinion Outer Race Installer (J-37758) and Drive Handle (J-8092). Place differential case assembly on hydraulic press using Differential Side Bearing Remover Plug (J-8107-4) for support. Place right side bearing onto right differential case, with taper side up, using Pinion Inner Bearing Race Installer (J-37759) and drive handle. Slowly press right differential side bearing onto right differential case.

Fig 3: Measuring Left Side Gear End Play
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: After proper end play is obtained, apply Loctite to ring gear bolts.
Install left differential case onto left side of differential case assembly using pinion outer race installer with drive handle and differential side bearing remover plug. Place differential case assembly on a hydraulic press with differential side bearing remover plug for support and to protect right side bearing. Place left side bearing onto left differential case, with taper side up, using pinion outer race installer with drive handle. Slowly press left side bearing onto case. Install inner pinion bearing race. Place differential carrier on a hydraulic press. Position inner pinion bearing race over its bore. Using pinion outer race installer with drive handle to slowly press inner pinion bearing race evenly into differential carrier.

NOTE: DO NOT overtighten pinion flange nut when adjusting bearing preload. Overtightening will result in collapsing NEW spacer.

Install outer pinion bearing race, evenly into differential carrier. Install pinion selective shim onto pinion gear shaft. Install inner pinion bearing onto pinion gear shaft with tapered side facing away from pinion gear. Install a NEW collapsible spacer onto pinion gear shaft with short shank toward pinion gear. Install outer pinion bearing and pinion gear into differential carrier. Install a NEW pinion oil seal and apply lubricant to seal lip. Adjust pinion bearing preload using Pinion Flange Remover Set (J-8614-01). Tighten nut gradually in increments of 44 INCH lbs. (5 N.m). Pinion gear should require 11 INCH lbs. (1.2 N.m) in order to rotate. Install side bearing races onto differential bearings. Install Differential assembly into differential carrier. Install both side bearing caps onto differential carrier, secure with four bearing cap bolts. See TORQUE SPECIFICATIONS .