Front

Disassembly

Fig. 17 Removing Axle Shaft:

Fig. 18 Removing Bevel Gear:

1. Remove front righthand driveshaft using plastic hammer and axle removal tool No. J37730 or equivalent, Fig. 17.
2. Remove differential assembly from housing.
3. Mount differential assembly, using differential holding tool Nos. J37769 and J3289-01 or equivalents.
4. Mark differential side bearing caps for installation.
5. Remove side bearing lock plate, caps, adjusters, outer races and bevel pinion and gear assembly.
6. Rotate differential assembly using flange holding tool No. J8614-01 or equivalent.
7. Remove universal joint flange nut, bevel pinion, flange and oil seal using seal removal tool Nos. J8614-01 and J26941 or equivalents.
8. Remove differential side bearing using bearing removal tool Nos. J22888 and J8107-4 or equivalents.
9. Remove bevel gear attaching bolts, then the gear, Fig. 18. When mounting differential in a vise, use aluminum plates to avoid damage.
10. Drive out spring pin. Disassemble differential side gears, pinions, washers and shaft in differential case.
11. Press out bevel pinion gear using side bearing remover tool No. J22912-01 or equivalent.
12. Drive out bevel pinion bearing outer race using suitable tools. Bevel gear and pinion must be replaced as a set.

Assembly

Fig. 19 Side Gear Thrust Measurement:

Fig. 20 Adjusting Bearing Preload:

Fig. 21 Bevel Pinion Mounting Distance:

1. Assemble bevel pinion bearing outer races using bearing installer tool Nos. J8092, J37759 and J37758 or equivalents.
2. Assemble differential side gear and side pinion with pinion shaft.
3. Mount dial indicator to top surface of side gear. Move lower end of side gear up and down, noting movement of indicator, Fig. 19.
4. Install a .043 inch thrust washer and ensure a .005-.014 inch side gear thrust play is obtained.
5. Drive spring pin in until it is flush with the differential case surface.
6. Install bevel gear to differential case and torque bolts to 70 ft. lbs.
7. Mount dial indicator tool to back of side gear, Fig. 20.
8. Install a .043 inch thrust washer and side thrust gear installation tool No. J35138 or equivalent onto differential side gear.
9. Move tool up and down in a straight forward manner and ensure a side gear thrust play of .005-.014 inch is obtained.
10. Install side bearings using bearing installation tool Nos. J8092 and J24433 or equivalent. Be sure to use side bearing removal tool No. J8107-4 or equivalent to protect the lower bearing.
11. Install depth gauge setting tool No. J21777 or equivalent while holding bearing in position, Fig. 21. Use low step on the gauge plate.
12. Torque tool nut to 19 inch lbs. and rotate gauge plate several times to seat bearings.
13. Torque tool nut to 19 inch lbs. or until gauge plate rotates smoothly with torque wrench.
14. Install pinion setting gauge tool No. J23597 or equivalent and assemble the gauge shaft in the carrier so that the dial indicator rod is centered on the gauging area of the gauge block.
15. Install side bearing caps and torque bolts to 63 ft. lbs.
16. Adjust dial indicator until a zero reading is obtained.
17. Adjust the position of gauge shaft mounting post so contact button touches the indicator pad.
18. Push the dial indicator downward into the gauge plate until the needle rotates 3/4 of a turn then tighten in this position.
19. Slowly rotate the gauge shaft back and forth. At the point of greatest deflection, reset the dial indicator to zero. Repeat and ensure zero reading.
20. Rotate the gauge shaft until the dial indicator rod no longer touches the gauge plate.
21. Read movement on the dial indicator. Total movement on the dial indicator indicates thickness of shim required.
22. Assemble pinion rear bearing, pinion shim and bevel pinion assembly.
23. Install front bearing to differential carrier with new spacer inserted.
24. Install oil seal into differential carrier until seal is flush with carrier end. Apply grease to lip of seal.
25. Install pinion washer and nut. Hold pinion flange and rotate pinion to seat bearing. Tighten pinion flange nut until endplay is taken up. Preload specification is reached when endplay is no longer detectable. No further tightening should be attempted until preload has been checked.
26. Using an inch lb. torque wrench, adjust bearing preload torque to 11 inch lbs.
27. Install bevel gear and differential case assembly, side bearing outer races, bearing adjusters and bearing caps, noting alignment mark.
28. Torque bearing caps bolts to 63 ft. lbs.

Fig. 22 Pre-adjusting Side Bearing:

Fig. 23 Combination Of Preloads:

29. Turn bearing adjuster to push side bearing lightly so that outer races are in contact with inner races, Fig. 22.
30. Measure preload of pinion with an inch pound torque wrench.
31. Adjust side bearing until gear backlash and bearing preload are within specifications, Fig. 23.
32. Install bearing lock plates.
33. Clean mating surfaces of housing and carrier and apply Suzuki Bond No. 1215 (part No. 99000-31110).
34. Position differential assembly in housing with two reamer bolts, then install six bolts, torquing to 17 ft. lbs.