Suzuki Grand Vitara JB416 / JB420. Manual — part 170
3B-33 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.
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: Rear 3B-34
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-35 Differential: Rear
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, 17.0
lb-ft)
Rear cover bolt No.2 (b): 60 N·m (6.0 kgf-m, 43.5
lb-ft)
25) Assembly rear drive right retainer as follows.
a) Install rear drive shaft bearing (1) using special
tool and press (2).
Special tool
(A): 09913–75520
b) Install snap ring.
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(a)
1
2
(b)
2, “A”
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2
(A)
1
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Differential: Rear 3B-36
c) Install oil seal using special tools as shown in
figure.
Distance between retainer surface and oil
seal
“a”: 2.5 – 3.0 mm (0.10 – 0.12 in.)
Special tool
(A): 09924–74510
(B): 09951–16090
26) Assembly rear drive left retainer in the same manner
at Step 25) in this assembly procedure.
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 left 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 left 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 rear drive right and left shaft using plastic
hammer.
Rear Differential Inspection
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Refer to “Front Differential Inspection: Front”.
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1
“A”
2
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“A”
2
1
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