Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 239

3B-27 Differential: Rear

d) Remove drive bevel pinion (1) with rear bearing,

shim and spacer from carrier.
If it is hard to remove, screw an used nut (2) into
drive bevel pinion and hammer (3) on that nut
with a plastic hammer but never directly on drive
bevel pinion.

e) Remove drive bevel pinion rear bearing (2) by

using bearing puller (3) and hydraulic press.

CAUTION

!

To avoid rear bearing from being damaged,
support it at flat side of bearing puller.

10) Remove oil seal (1) using special tool.

Special tool
(A): 09913–50121

11) Using a hammer and brass bar (1), drive out front

bearing outer race (2).

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

manner as Step 11).

1. Drive bevel pinion

3

2

1

I5JB0A321018-01

I1JA01322006-01

(A)

1

I5JB0A321019-01

I5JB0A321020-01

I5JB0A321021-01

Differential: Rear 3B-28

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): 200 N·m (20.0 kgf-m, 145.0
lb-ft)

1. Differential carrier

(B)

(A)

1

(C)

I5JB0A321022-01

I5JB0A321023-05

1

I6JB01322003-01

2, (a), “A”

3

1

I5JB0A321025-01

3B-29 Differential: Rear

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

Differential: Rear 3B-30

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

6. Spacer

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

2. Nut

7. Drive bevel pinion

“c”: Measured dimension

3. Front bearing

8. Drive bevel gear

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

4. Differential carrier

“a”: Pinion dummy height + Attachment height

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

5. Rear bearing

“b”: Axle dummy radius