Suzuki Grand Vitara JB416 / JB420. Manual - part 164

3B-9 Differential: Front

5) Install special tool to differential case assembly (2) 

and check that preload is within specification. If 
preload exceeds specified value, check if foreign 
matter is caught or gear is damaged.

Special tool
(B):  09928–06510

Side 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: Front 3B-10

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

8. Drive bevel gear

2. Nut

“a”: Pinion dummy height + Attachment height

3. Front bearing

“b”: Axle dummy radius

4. Differential carrier

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

5. Rear bearing

“c”: Measured dimension

6. Spacer

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

7. Drive bevel pinion

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

3B-11 Differential: Front

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

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.

 

4. Socket with adapter

I5JB0A321030-01

I5JB0A321031-01

IYSQ01322033-01

Differential: Front 3B-12

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.
“1 mm (0.039 in.)” is “a” + “b” (Mounting dummy size) 
– “d” (Drive bevel pinion mounting distance)

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.

 

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

Necessary 

shim thickness 

“e”

= 1 mm (0.039 in.) +

Dial gauge 

measured 

value “c” 

3. Drive bevel pinion

(F)

(D)

(B)

(A)

I5JB0A321032-01

I5JB0A321033-01

1. Drive bevel pinion
2. Rear bearing

I5JB0A321034-01

I5JB0A321035-01