Drive Bevel Pinion

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

To engage bevel pinion and gear correctly, it is pre-required to install bevel pinion to differential carrier properly by using adjusting shim as described in the following. Shown in the figure of Step 5 are relative positions of bevel pinion, differential carrier and mounting dummy.

Install special tools with bearings and universal joint flange to differential carrier (1).
NOTE:
- This installation requires universal joint flange (2) not equipped with groove on flange periphery.
- This installation requires no spacer or oil seal.
Special tool

(B): 09926-78311

(F): 09951-46010

Fig 1: Installing Special Tools With Bearings & Universal Joint Flange To Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Tighten flange nut (1) so that specified bearing preload is obtained. See Fig 2 .
NOTE: Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of oil to bearings.

Special tool

(B): 09926-78311

(C): 09922-75222

Pinion bearing preload

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 2: Tightening Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.
Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate. See Fig 3 .
NOTE:
- When setting dial gauge to mounting dummy, tighten screw 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

Fig 3: Setting Dial Gauge To Bevel Pinion Mounting
Courtesy of SUZUKI OF AMERICA CORP.
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 4 .
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): 09900-20606

(B): 09926-78311

(D): 09951-16070

(E): 09922-77250

Fig 4: Placing Zero-Adjusted Mounting Dummy & Dial Gauge Set On Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Obtain adjusting shim thickness by using measured value by dial gauge (which represents "c" in figure) in the following equation.
Necessary shim thickness "e" = Dial gauge measured value "c"

Special tool

(A): 09900-20606

(B): 09926-78311

(C): 09922-75222

(D): 09951-16070

(E): 09922-77250

(F): 09951-46010

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

Calculated value "g"

Closest value to "e" (Refer to Step 5 .)

Special tool

(G): 09925-18010

(H): 09927-66010

Fig 6: Installing Adjusting Shim
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 oil to bearings.
Fig 7: 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 8: Driving Oil Seal Into Differential Carrier Using Special Tool & Hammer
Courtesy of SUZUKI OF AMERICA CORP.
While tightening flange nut gradually with special tool (J) and power wrench (4-10 magnification (1)), set preload of pinion to specification. See Fig 9 .
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

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 - 34 N (1.8 - 3.4 kg, 4.0 - 7.5 lb)

Special tool

(C): 09922-75222

(J): 09922-66020

Fig 9: Tightening Flange Nut With Special Tool
Courtesy of SUZUKI OF AMERICA CORP.