Suzuki Grand Vitara JB627. Manual — part 143

3B-14 Differential: Front

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.

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A: Paint gear marking compound evenly

1

A

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Differential: Front 3B-15

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.

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3B-16 Differential: Front

23) Upon completion of gear tooth contact check in Step

22), caulk flange nut (2) with caulking tool (1) and
hammer.

24) Clean mating surface of differential carrier (2) and

rear cover (1), apply sealant to carrier as shown in
figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate rear cover with
differential carrier, and then tighten bolts to specified
torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Rear cover bolt No.1 (a): 50 N·m (5.0 kgf-m, 36.5
lb-ft)
Rear cover bolt No.2 (b): 60 N·m (6.0 kgf-m, 43.5
lb-ft)

25) Assembly front drive shaft retainer as follows.

a) Install front drive shaft bearing (1) using special

tool, and then install snap ring.

Special tool
(A): 09913–75520

b) Apply grease to oil seal lip, and then install oil

seal (1) using special tools as shown in figure.

Distance between retainer surface and oil
seal
“a”: 4.7 – 5.2 mm (0.185 – 0.205 in.)

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

Special tool
(A): 09924–74510
(B): 09951–16090

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(a)

1

2

(b)

2, “A”

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(A)

1

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Differential: Front 3B-17

26) Apply grease to oil seal lip, and then install oil seal

into differential side right retainer (1) as shown in
figure.

Distance between retainer surface and oil seal
“a”: 0.65 – 1.65 mm (0.026 – 0.065 in.)

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

Special tool
(A): 09913–75520

27) Clean mating surface of right retainer, carrier (1) and

rear cover (2), apply sealant to carrier and rear cover
as shown in figure by such amount that its section is
1.5 mm (0.059 in.) in diameter, mate right retainer
with carrier and rear cover, and then tighten bolts to
specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Retainer bolt: 50 N·m (5.0 kgf-m, 36.5 lb-ft)

28) Clean mating surface of front drive shaft retainer,

carrier (1) and rear cover (2), apply sealant to carrier
and rear cover as shown in figure by such amount
that its section is 1.5 mm (0.059 in.) in diameter,
mate front drive shaft retainer with carrier and rear
cover, and then tighten bolts to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Retainer bolt: 50 N·m (5.0 kgf-m, 36.5 lb-ft)

29) Install front drive shaft using plastic hammer.
30) Install front differential rear mounting (1).

Tightening torque
Rear mounting bracket bolt (a): 50 N·m (5.0 kgf-
m, 36.5 lb-ft)

31) Install front differential right mounting (1).

Tightening torque
Right mounting bracket bolt (b): 50 N·m (5.0 kgf-
m, 36.5 lb-ft)

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1

“A”

2

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“A”

2

1

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(a)

1

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1

(b)

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