Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 240
3B-31 Differential: Rear
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
Differential: Rear 3B-32
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.
Necessary
shim
thickness
“e”
=
Mounting
dummy size
103.0 mm/
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
3B-33 Differential: Rear
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
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.
I5JB0A321035-01
2. Socket wrench
I5JB0A321036-02
I6JB01321003-02
Differential: Rear 3B-34
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.)
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
A: Paint gear marking compound evenly
I5JB0A321039-01
1
A
I5JB0A321040-02
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