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