Suzuki Grand Vitara JB416 / JB420. Manual — part 165

3B-13 Differential: Front

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

Differential: Front 3B-14

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.

I5JB0A321038-03

I5JB0A321039-01

A: Paint gear marking compound evenly

1

A

I5JB0A321040-02

3B-15 Differential: Front

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

Differential: Front 3B-16

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

I1JA01322021-01

(a)

1

2

(b)

2, “A”

I6JB01321001-03

(A)

1

I5JB0A321043-01

I5JB0A321044-01