Suzuki Grand Vitara JB627. Manual — part 147

3B-30 Differential: Rear

12) 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.

Special tool
(A): 09900–20607
(B): 09926–78311
(D): 09951–16070
(F): 09926–78311–002
: 09922–76520

13) Obtain adjusting shim thickness by the following

equation.

14) 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).

Special tool
(G): 09913–85210
(H): 09940–53111

Available shim thickness
1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21,1.24,
1.27, 1.30 and 0.3 mm
(0.039, 0.040, 0.042, 0.043, 0.044, 0.045, 0.046,
0.047 0.048, 0.049, 0.050 and 0.012 in.)

15) 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.

16) Using special tool and plastic hammer, drive oil seal

(2) into differential carrier (1) as shown in figure.
Then apply grease “A” to oil seal lip.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)

Special tool
(A): 09951–18210

Necessary

shim

thickness

“e”

=

Mounting

dummy size

103.0mm /

4.0551 in.

“a” + “b”

+

Measured

dimension

“c”

–

Drive bevel

pinion

mounting

distance

102 mm /

4.0157 in.

(F)

(D)

(B)

(A)

I5JB0A321032-01

3. Drive bevel pinion

1. Drive bevel pinion
2. Rear bearing

I5JB0A321033-01

I5JB0A321034-01

I5JB0A321035-01

Differential: Rear 3B-31

17) 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
20 – 40 N (2.0 – 4.0 kg, 4.4 – 8.8 lb)

Special tool
(A): 09922–75222
(B): 09922–66021

18) Select differential side bearing shim as follows.

a) Measure dimension “a” and “b” using vernier

caliper.

b) Calculate dimension “a” – “b”, and select shims

from among following available size so that total
of thickness of right side and left side shims may
reach the calculated value.

NOTE
Select shims so that thickness of right side
shims and left side shims become almost
even.

Available shim thickness
Right side: 1.75, 1.85, 1.95, 2.00, 2.05, 2.15
and 2.25 mm (0.069, 0.073, 0.077, 0.079, 0.081,
0.085 and 0.089 in.)
Left side: 2.75, 2.85, 2.95, 3.00, 3.05, 3.15 and
3.25 mm (0.108, 0.112, 0.116, 0.118, 0.120,
0.124 and 0.128 in.)

2. Socket wrench

I5JB0A321036-02

I5JB0A321037-04

3B-32 Differential: Rear

19) To measure bevel gear backlash, set dial gauge (1)

at right angle to bevel gear tooth, fix drive bevel
pinion and read dial gauge while moving bevel gear.

Special tool
(A): 09900–20607
(B): 09900–20701

Bevel gear backlash
: 0.1 – 0.2 mm (0.004 – 0.008 in.)

NOTE

• Be sure to apply measuring tip of dial

gauge at right angles to convex side of
tooth.

• Measure at least 4 points on drive bevel

gear periphery.

• If backlash exceeds specification given

below, adjust it by changing thickness
ratio of differential side bearing shims.

20) Place bearing outer races on their respective

bearings. Used left and right outer races are not
interchangeable.

21) Install case assembly (1) in carrier (2).

22) As final step, check gear tooth contact as follows.

a) After cleaning 10 drive bevel gear teeth, paint

them with gear marking compound evenly by
using brush (1) or sponge etc.

b) Turn gear to bring its painted part in mesh with

drive bevel pinion and turn it back and forth by
hand to repeat their contact.

c) Bring painted part up and check contact pattern,

referring to the following table. If contact pattern
is not normal, readjust or replace as necessary
according to instruction in the table.

NOTE
Be careful not to turn drive bevel gear more
than one full revolution, for it will hinder
accurate check.

I5JB0A321038-03

I5JB0A321039-01

A: Paint gear marking compound evenly

1

A

I5JB0A321040-02

Differential: Rear 3B-33

Tooth Contact Pattern

Diagnosis and Remedy

Normal

High Contact
Pinion is positioned too far from the center of drive
bevel gear (1).
• Increase thickness of pinion (2) height adjusting

shim and position pinion closer to gear center.

• Adjust drive bevel gear backlash to specification.

Low Contact
Pinion is positioned too close to the center of drive
bevel gear (1).
• Decrease thickness of pinion (2) height adjusting

shim and position pinion farther from gear center.

• Adjust drive bevel gear backlash to specification.

If adjustment is impossible, replace differential carrier.

• Check seating of bevel gear or differential case. (Check bevel

gear for runout.)

• If adjustment is impossible, replace drive bevel gear and pinion

set or differential carrier.

Replace drive bevel gear and pinion set or differential case.

I5JB0A321041-05

IYSQ01321072-01

IYSQ01321073-01

IYSQ01321074-01

IYSQ01321076-01

IYSQ01321077-01

IYSQ01321078-01

IYSQ01321079-01