Suzuki Grand Vitara JB627. Manual - part 146

3B-26 Differential: Rear

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

manner as Step 11).

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):  Tighten 40 N

⋅m (4.0 kgf-m, 

29.5 lb-ft) + 50

° 

1. Differential carrier

I5JB0A321021-01

(B)

(A)

1

(C)

I5JB0A321022-01

I5JB0A321023-05

1

I5JB0A322015-01

2, (a), “A”

3

1

I5JB0A321025-01

Differential: Rear 3B-27

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

3B-28 Differential: Rear

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)

Differential: Rear 3B-29

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

4. Socket with adapter

I5JB0A321030-01

I5JB0A321031-01

IYSQ01322033-01