Drive Bevel Pinion

To engage bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described in the following. Shown in the figure of Step  4 are relative positions of bevel pinion, differential carrier and mounting dummy.

1. Install bevel pinion dummy with bearings into differential carrier and tighten flange nut (1) so that specified bearing preload is obtained.
   NOTE:

   • This installation requires universal joint flange not equipped with groove on flange periphery.
   • This installation requires no spacer or oil seal.
   • Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of oil to bearings. See Fig 1 .

   Special tool 

   (A): 09922-75222 

   (B): 09926-78311 

   Pinion bearing preload

   (A): 9.0 - 17.0 kg-cm (7.8 - 14.7 lb-in.) 

   Spring measure reading

   1.8 - 3.4 kg (4.0 - 7.5 lb) 

   Fig 1: Checking Rotation By Hand

   Courtesy of SUZUKI OF AMERICA CORP.
2. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate.
   NOTE:

   • When setting dial gauge to mounting dummy, tighten screw lightly. See Fig 2 . 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 

   (C): 09926-78311 

   (D): 09900-20606 

   Fig 2: Setting Dial Gauge To Mounting Dummy

   Courtesy of SUZUKI OF AMERICA CORP.
3. Place zero-adjusted mounting dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip. See Fig 3 .
   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 

   (C): 09926-78311 

   (D): 09900-20606 

   Fig 3: Placing Zero-Adjusted Mounting Dummy & Dial Gauge Setting On Pinion Dummy

   Courtesy of SUZUKI OF AMERICA CORP.
4. Obtain adjusting shim thickness by using measured value by dial gauge (which represents "c" in figure) in the following equation. See Fig 4 .

   Necessary shim thickness "e" = Dial gauge measured value "c"

   Special tool 

   (A): 09900-20606 

   (B): 09926-78311 

   (C): 09922-75222 

   Fig 4: Adjusting Shim Thickness Using Measured Value by Dial Gauge

   Courtesy of SUZUKI OF AMERICA CORP.
5. Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit front bearing (1). See Fig 5 .

   Special tool 

   (E): 09925-18010 

   (F): 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, 0.048 0.049, 0.050, 0.051 and 0.012 in.) 

   Fig 5: Selecting Adjusting Shim(s)

   Courtesy of SUZUKI OF AMERICA CORP.
6. With new pinion spacer (3) inserted as shown, install rear bearing (5) to differential carrier (4).
   NOTE:

   • Make sure to use new spacer for reinstallation.
   • Apply oil to bearings.
   Fig 6: Installing Rear Bearing To Differential Carrier

   Courtesy of SUZUKI OF AMERICA CORP.
7. Using special tool and plastic hammer drive oil seal (2) into differential carrier (1) till it becomes flush with carrier end. Then apply grease to oil seal lip.

   Special tool 

   (G): 09951-18210 

   "A": Grease 99000-25010 

   Fig 7: Driving Oil Seal Into Differential Carrier Using Special Tool & Hammer

   Courtesy of SUZUKI OF AMERICA CORP.
8. While tightening flange nut gradually with flange holder (special tool) and power wrench (4-10 magnification) (1), set preload of pinion to specification.See Fig 8 .
   NOTE:

   • Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand.
   • Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange.
   • Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.

Pinion bearing preload

9.0 - 17.0 kg-cm (7.8 - 14.7 lb-in.) 

Spring measure reading

1.8 - 3.4 kg (4.0 - 7.5 lb) 

Special tool 

(A): 09922-75222 

(H): 09922-66020 

Fig 8: Setting Preload Of Pinion

Courtesy of SUZUKI OF AMERICA CORP.