Suzuki Grand Vitara JB627. Manual — part 146

3B-26 Differential: Rear

12) Drive out rear bearing outer race (1) in the same

manner as Step 11).

Reassembly
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.

1) For press-fitting drive bevel pinion bearing outer

races, use special tools and press as shown in the
figure.

Special tool
(A): 09924–74510
(B): 09925–14520
(C): 09913–75510

2) After applying differential oil to differential gear (4),

pinions (5), pinion shafts (6), pinion washer, thrust
washer (2) and spring washer (1), install them in
differential right case (3).
For correct installing direction of thrust washer (2)
and spring washer (1), refer to the figure.

3) Check differential pinion gear (1) for smooth rotation.

4) Put drive bevel gear (3) on differential case (1) and

fasten them with bolts (2) by tightening them to
specified torque. Use thread lock cement for bolts
(2).

CAUTION

!

Use of any other bolts than that specified is
prohibited.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)

Tightening torque
Bevel gear bolt (a): Tighten 40 N

⋅m (4.0 kgf-m,

29.5 lb-ft) + 50

°

1. Differential carrier

I5JB0A321021-01

(B)

(A)

1

(C)

I5JB0A321022-01

I5JB0A321023-05

1

I5JB0A322015-01

2, (a), “A”

3

1

I5JB0A321025-01

Differential: Rear 3B-27

5) Install special tool to differential case assembly (2)

and check differential gear for preload. If preload
exceeds specified value, check if foreign matter is
caught or gear is damaged.

Special tool
(B): 09928–06510

Differential gear preload
Max. 2.5 N

⋅m (0.25 kgf-m, 1.8 lb-ft)

6) Press-fit left side bearing (1) with special tool and

hydraulic press.

Special tool
(A): 09913–75821
(B): 09924–84510–004

7) Press-fit right side bearing (1) with special tools and

hydraulic press.

NOTE
Be sure to use bearing holder for the purpose
of protecting lower bearing.

Special tool
(A): 09913–75821
(B): 09924–84510–004
(C): 09924–84510–005

1. Torque wrench
3. Aluminum plate
4. Vise

I5JB0A321026-01

(B)

(A)

1

I5JB0A321027-01

(B)

(A)

1

(C)

I5JB0A321028-02

3B-28 Differential: Rear

8) 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.

Special tool
(A): 09900–20607
(B): 09926–78320
(C): 09922–75222
(D): 09951–16070
(E): 09951–46010
(F): 09926–78311–002
(G): 09922–76520

(A)

(B)

(D)

(F)

(E)

2

(G)

“a”

“b”

“d”

“e”

“c”

(C)

1

5

4

3

8

7

6

I5JB0A321029-02

1. Universal Joint flange

8. Drive bevel gear

2. Nut

“a”: Pinion dummy height + Attachment height

3. Front bearing

“b”: Axle dummy radius

4. Differential carrier

“a” + “b”: Mounting dummy size 103.0 mm/4.0551 in.

5. Rear bearing

“c”: Measured dimension

6. Spacer

“d”: Drive bevel pinion mounting distance 102.0 mm/4.0157 in.

7. Drive bevel pinion

“e”: Shim size for mounting distance adjustment (= “c” + 1)

Differential: Rear 3B-29

9) Install special tools with bearings (3) and flange (2)

to differential carrier (1).

NOTE
This installation requires no spacer or oil
seal.

Special tool
(E): 09951–46010
(F): 09926–78311–002

10) 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

bevel pinion about 1 rotation per 2
seconds.

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
20 – 40 N (2.0 – 4.0 kg, 4.4 – 8.8 lb)

11) 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): 09900–20607
(B): 09926–78320

4. Socket with adapter

I5JB0A321030-01

I5JB0A321031-01

IYSQ01322033-01