Drive Bevel Pinion

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

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.

For H25 engine model

Special tool

(A): 09900-20606

(B): 09926-78311

(C): 09922-75222

(D): 09951-16070

(E): 09922-77250

(F): 09951-46010

Fig 1: Setting Drive Bevel Pinion Depth (For H25 Engine Model)

Courtesy of SUZUKI OF AMERICA CORP.

For H27 engine model

Special tool

(A): 09900-20606

(B): 09926-78320

(C): 09922-75222

(D): 09922-76570

(E): 09951-46010

(F): 09926-78311-002

Fig 2: Setting Drive Bevel Pinion Depth (For H27 Engine Model)

Courtesy of SUZUKI OF AMERICA CORP.

Install special tools with bearings and universal joint flange (2) to differential carrier (1).
NOTE: This installation requires no spacer or oil seal.

For H25 engine model

Special tool

(B): 09926-78311

(F): 09951-46010 (for M/T model only)

Fig 3: Exploded View Of Drive Bevel Pinion Components (For H25 Engine Model)
Courtesy of SUZUKI OF AMERICA CORP.

For H27 engine model

Special tool

(E): 09951-460410

(F): 09926-78311-002

Fig 4: Exploded View Of Drive Bevel Pinion Components (For H27 Engine Model)
Courtesy of SUZUKI OF AMERICA CORP.
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 pinion about 1 rotation per 2 seconds.
For H25 engine model

Special tool

(B): 09926-78311

(C): 09922-75222

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

Spring measure reading with special tool: 1.8 - 3.4 kg (4.0 - 7.5 lb)

Fig 5: Measuring Bearing Preload (For H25 Engine Model)
Courtesy of SUZUKI OF AMERICA CORP.

For H27 engine model

Special tool

(C): 09922-75222

(F): 09926-78311-002

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

Spring measure reading with special tool: 18 N - 34 N (1.8 - 3.4 kg, 4.0 - 7.5 lb)

Fig 6: Measuring Bearing Preload (For H27 Engine Model)
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): 09900-20606

(B): 09926-78311 (for H25 engine model)

(B): 09926-78320 (for H27 engine model)

Fig 7: Making 0 (Zero) Adjustment To Bevel Pinion Mounting Dummy
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.
For H25 engine model

Special tool

(A): 09900-20606

(B): 09926-78311

(D): 09951-16070

(E): 09922-77250

Fig 8: Using Pinion Mounting Dummy To Measure Between Zero Position And Extended Dial Gauge Measuring Tip (For H25 Engine Model)
Courtesy of SUZUKI OF AMERICA CORP.

For H27 engine model

Special tool

(A): 09900-20606

(B): 09926-78311

(D): 09922-76570

(F): 09926-78311-002

Fig 9: Using Pinion Mounting Dummy To Measure Between Zero Position & Extended Dial Gauge Measuring Tip (For H27 Engine Model)
Courtesy of SUZUKI OF AMERICA CORP.
Obtain adjusting shim thickness by the following equation.
For H25 engine model

"102" in equation below is "a" + "b" of mounting dummy

Necessary shim thickness "f" = 102 + Dial gauge measured value "c" Measurement printed on pinion "e"

For H27 engine model

Necessary shim thickness "e" = Dial gauge measured value "c"
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).
For H25 engine model

Calculated value "g" (For H25 engine model)
Closest value to "f" (refer to Step 5).
Calculated value "f" (For H27 engine model)

"f": Closest value to "e" (refer to Step 5)

Special tool

(G): 09925-18011

(H): 09927-66010

Available shim thickness: 1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 and 0.3 mm (0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)

Fig 10: Installing Bearing And Shims
Courtesy of SUZUKI OF AMERICA CORP.
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.
Fig 11: Installing Front Bearing To Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) till it becomes flush with carrier end. Then apply grease "A" to oil seal lip.
"A": Grease 99000-25010

Special tool

(I): 09951-18210

Fig 12: Driving Oil Seal Into Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
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 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)

Spring measure reading with special tool

For H25 engine model: 18 - 34 N (1.8 - 3.4 kg, 4.0 - 7.5 lb)

For H27 engine model: 16 - 30 N (1.6 - 3.0 kg, 3.5 - 6.6 lb)

Special tool

(C): 09922-75222 (for H25 engine model)

(C): 09922-76560 (for H27 engine model)

(J): 09922-66021

Fig 13: Measuring Bearing Preload
Courtesy of SUZUKI OF AMERICA CORP.