2006 SUZUKI SX4 PPL

Downloaded from www.Manualslib.com manuals search engine 3B-35 Differential:
Rear Differential ComponentsS6RW0D3206013
4 5
9
2
30
6
(a)13
12
(a)
3
A
3A
141617 2118
29
3A
1(b)
22
1217G
101217G
11
8OIL
15OIL
19 20OIL
23OIL
25OIL27OIL
27OIL
25OIL
19OIL18
26 28
OIL
26OIL23OIL
24OIL
(c)
14
7
I5RW0A320026-02
1. Flange nut 13. Differential cover bolt 25. Differential gear
2. Companion flange 14. Spacer 26. Spring washer
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.15. Rear bearing 27. Thrust washer
4. Coupling front bearing 16. Shim 28. Pinion shaft
5. Coupling case
: Apply sealant 99000-31260 to mating surface of carrier and coupling
case.17. Bevel pinion 29. Pinion shaft pin
6. Coupling assembly
: Never disassemble.18. Shim 30. Coupling case bolt
7. Snap ring 19. Differential side bearing : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
8. Bevel pinion nut
: Tighten nut so as rotation torque of bevel pinion to be in specified value.20. Bevel gear : 125 N⋅m (12.5 kgf-m, 90.5 lb-ft)
9. Front bearing 21. Differential case : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
10. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear cover.22. Bevel gear bolt : Do not reuse.
11. Coupling air temperature sensor 23. Pinion washer : Apply differential oil.
12. Differential cover 24. Pinion

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-38
14) Using a hammer and brass bar (1), drive out front
bearing outer race (2).
15) Using a hammer and brass bar (1), drive out rear
bearing outer race (2).
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 in the following.
CAUTION!
• Bevel gear and pinion must be replaced as
a set when either replacement becomes
necessary.
• When replacing taper roller bearing,
replace as inner race & outer race
assembly.

1) Press-fit bevel pinion bearing outer races to
differential carrier (1) by using special tools and
hydraulic press as shown in the figure.
Special tool
(A): 09913–85210
(B): 09913–75510
2) After applying differential oil to differential gears (4),
pinions (5), pinion shaft (3), side washers (1), spring
washers (7) and pinion washers (2), install them in
differential case (6).
For correct installing direction of side washers and
spring washers, refer to figure.
NOTE
Used left and right differential side washers
are not interchangeable.

3) Check pinion gear (1) for smooth rotation.
1
2
I5RW0A320038-01
1
2
I5RW0A320039-01
(B)(A)
1
I5RW0A320040-02
7 6
4
5
3
21
I5RW0A320041-01
I3RH01322031-01

Downloaded from www.Manualslib.com manuals search engine 3B-41 Differential:
9) Set special tools and make drive bevel pinion
mounting dummy.
Special tool
(A): 09922–76120
(B): 09922–76250
10) Install dial gauge (1) to mounting dummy as shown
in figure.
Special tool set distance
“a”: 38.0 mm (1.496 in.)
“b”: 0 mm (0.000 in.)
11) Set special tools and make drive bevel pinion
dummy.
Special tool
(A): 09922–76140
(B): 09922–76420
(C): 09922–76330
(D): 09922–7634012) Apply gear oil to drive bevel pinion bearings, install
special tools with bearings to differential carrier as
shown in figure.
Special tool
(A): 09922–76140
(B): 09922–76420
(C): 09922–76330
(D): 09922–76340
(E): 09922–76150
(F): 09922–76530
NOTE
This installation requires no spacer or oil
seal.

13) Tighten bevel pinion nut (special tool) (1) so that
specified bearing preload is obtained.
NOTE
Before taking measurement, check for
rotation by hand more than 15 revolutions.

Pinion bearing preload (at 50 r/min)
: 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb-
in.)
I5RW0A320047-01
(C)
(D)
(A)
(A)(B)I5RW0A320048-01
(E) (D) (C)(B) (A) (F)I5RW0A320049-01
1
I5RW0A320050-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-42
14) Set dial gauge to bevel pinion mounting dummy and
make 0 (zero) adjustment on surface plate.
NOTE
• When setting dial gauge to mounting
dummy, tighten screw lightly. Be careful
not to overtighten it, which will cause
damage to dial gauge.
• With dial gauge set, turn dummy back and
forth 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).

15) Place zero-adjusted mounting dummy (1) and dial
gauge set on pinion dummy (2) and take
measurement between zero position and extended
dial gauge measuring tip.
NOTE
• Repeat turning back and forth 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.

16) Necessary adjusting shim thickness is the same
value as measured value by dial gauge.
17) Select adjusting shim(s) (2) closest to obtained value
from among the following available sizes and put it in
place and then press-fit rear bearing (1) to bevel
pinion (3).
Available shim thickness
0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81,
0.84 and 0.87 mm (0.012, 0.023, 0.024, 0.026,
0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034
in.)
Special tool
(D): 09925–18011
18) With new pinion spacer (2) inserted as shown in
figure, install front bearing (1) to differential carrier
(3).
NOTE
Apply differential oil to front and rear
bearings.

I5RW0A320051-01
1
2
I5RW0A320052-01
Necessary shim thickness
“e”= Dial gauge measured
value “c”
I3RH01322055-01
I5RW0A320053-01

Downloaded from www.Manualslib.com manuals search engine 3B-43 Differential:
19) Using special tool and plastic hammer, drive oil seal
(2) into differential carrier (1) as shown in figure.
Then apply grease to oil seal lip.
NOTE
Install oil seal horizontally to surface of
differential carrier.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between differential carrier and oil seal
“a”
: 0.5 – 1.5 mm (0.02 – 0.06 in.)
Special tool
(A): 09913–85210
20) Tighten bevel pinion nut (1) gradually with special
tool to specified torque while turning bevel pinion.
Set bearing preload of bevel pinion to specification.
NOTE
• Before taking measurement with torque
wrench, check for smooth rotation with
turning bevel pinion 15 revolutions or
more by hand.
• Be sure to tighten gradually and carefully
till specified pinion bearing preload is
obtained. Turning back overtightened
flange nuts should be avoided.
• Measure pinion bearing preload while
turning bevel pinion about 50 rpm.
• Write down measured value of bevel pinion
bearing preload for differential side
bearing shim adjustment.

Special tool
(A): 09927–27910
Tightening torque
Bevel pinion nut: 230 – 340 N·m (23.0 – 34.0 kgf-
m, 166.5 – 246.0 lb-ft)
Bevel pinion bearing preload (Bevel pinion
rotational torque)
: 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb-
in.)
21) Install differential case assembly, bearing outer
races, removed shim and differential cover,
temporarily.
NOTE
• Used left and right outer races are not
interchangeable.
• When measuring bevel pinion bearing
preload, install differential cover with
sealant not applied.

22) Select differential side bearing shim so that bevel
pinion bearing preload may be specified value.
NOTE
Select shims so that thickness of right side
shims and left side shims become almost
even.

Bevel pinion bearing preload
Preload measured in Step 20) + 0.3 – 0.7 N⋅m (3 –
7 kgf-cm, 2.6 – 6.0 lb-in.)
Available shim thickness
0.45, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65
and 2.70 mm (0.017, 0.090, 0.092, 0.094, 0.096,
0.098, 0.100, 0.102, 0.104 and 0.106 in.)
(A)
11
2, “A”
“a”
I5RW0A320054-02
(A)
1
I5RW0A320055-03
I5RW0A320056-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-44
23) Remove differential cover.
24) To measure bevel gear backlash, set dial gauge at
right angle to bevel gear tooth, fix drive bevel pinion
and read dial gauge while moving bevel gear.
If bevel gear backlash is out of specification, repeat
Step 22).
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.

Drive bevel gear back lash
0.1 – 0.2 mm (0.004 – 0.008 in.)Special tool
(A): 09900–20607
(B): 09900–20701
25) 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.

I5RW0A320057-01
A: Paint gear marking compound evenly
1
A
I5JB0A321040-02

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-46
26) Clean mating surface of differential carrier (1) and
differential cover, apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate differential cover with
differential carrier, and then tighten bolts to specified
torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Differential cover bolt: 23 N·m (2.3 kgf-m, 17.0
lb-ft)
27) Assemble coupling case as follows.
a) Install bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
b) Install snap ring using snap ring pliers.
c) Apply grease to oil seal lip, install oil seal (2) to
coupling case (1) using special tool as shown in
figure.
NOTE
Install oil seal horizontally to surface of
coupling case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between case and oil seal “a”
: 1.5 – 2.5 mm (0.06 – 0.10 in.)
Special tool
(A): 09913–7581028) Install spacer (1) to coupling assembly (2) as shown
in figure.
29) Install grommet of coupling harness into groove of
coupling case and then install coupling assembly by
using hydraulic press.
30) Install companion flange to pinion, and then hold
companion flange with special tool and tighten flange
nut.
Tightening torque
Flange nut: 110 N·m (11.0 kgf-m, 79.5 lb-ft)
Special tool
(A): 09930–40113
“A”
1
I5RW0A320058-02
(A)
I5RW0A320059-02
(A)
1 12, “A”“a”
I5RW0A320060-02
12
12
I5RW0A320065-01
(A)
I5RW0A320061-01

Downloaded from www.Manualslib.com manuals search engine 3B-47 Differential:
31) Clean mating surface of differential carrier (1) and
coupling case (2), apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate coupling case with
differential carrier as shown in figure, and then
tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
NOTE
Install coupling pin (3) by fitting it to groove
(4) of coupling case.

32) Apply grease to oil seal lip, and then install oil seals
(1) to rear differential (2) using special tool as shown
in figure.
NOTE
Install oil seal horizontally to surface of rear
differential case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between rear differential and oil seal
“a”
: 1.0 – 2.0 mm (0.04 – 0.08 in.)
Special tool
(A): 09913–75810
33) Install drive shaft flange.
34) Install rear mounting bracket to rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
Rear Differential InspectionS6RW0D3206015
• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.
• Check drive bevel pinion and bevel gear for wear or
cracks.
• Check side gears, pinion gears and pinion shaft for
wear or damage.
• Check side gear spline for wear or damage.
1 4
3 2“A”
(a)
I5RW0A320062-04
(A)
2 21, “A”
“a”
I5RW0A320063-02