Suzuki Grand Vitara JB416 / JB420. Manual - part 170

3B-33 Differential: Rear

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.

 

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A: Paint gear marking compound evenly

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Differential: Rear 3B-34

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.

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3B-35 Differential: Rear

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, 17.0 
lb-ft)
Rear cover bolt No.2 (b):  60 N·m (6.0 kgf-m, 43.5 
lb-ft)

25) Assembly rear drive right retainer as follows.

a) Install rear drive shaft bearing (1) using special 

tool and press (2).

Special tool
(A):  09913–75520 

b) Install snap ring.

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(a)

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2

(b)

2, “A”

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Differential: Rear 3B-36

c) Install oil seal using special tools as shown in 

figure.

Distance between retainer surface and oil 
seal
“a”: 2.5 – 3.0 mm (0.10 – 0.12 in.)

Special tool
(A):  09924–74510 
(B):  09951–16090 

26) Assembly rear drive left retainer in the same manner 

at Step 25) in this assembly procedure.

27) Clean mating surface of right retainer, carrier (1) and 

rear cover (2), apply sealant to carrier and rear cover 
as shown in figure by such amount that its section is 
1.5 mm (0.059 in.) in diameter, mate right retainer 
with carrier and rear cover, and then tighten bolts to 
specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G) 

Tightening torque
Retainer bolt:  50 N·m (5.0 kgf-m, 36.5 lb-ft)

28) Clean mating surface of left retainer, carrier (1) and 

rear cover (2), apply sealant to carrier and rear cover 
as shown in figure by such amount that its section is 
1.5 mm (0.059 in.) in diameter, mate left retainer with 
carrier and rear cover, and then tighten bolts to 
specified torque.

“A”:  Sealant 99000–31260 (SUZUKI Bond 
No.1217G) 

Tightening torque
Retainer bolt:  50 N·m (5.0 kgf-m, 36.5 lb-ft)

29) Install rear drive right and left shaft using plastic 

hammer.

Rear Differential Inspection

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Refer to “Front Differential Inspection: Front”.

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1

“A”

2

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“A”

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