Transfer Output Retainer Assembly Disassembly and Reassembly: Reassembly

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 and outer race assembly.

To mesh bevel gears correctly, it is prerequired to install bevel pinion to transfer output retainer properly by using adjusting shim (bevel pinion shim) as follows.
1. Install front taper roller bearing (1) to bevel pinion dummy (special tools).
  Special Tool
  1. 09922-76140
  2. 09922-76430
    
    Fig 1: Identifying Front Taper Roller Bearing
    Courtesy of SUZUKI OF AMERICA CORP.
2. Install bevel pinion dummy (1), rear taper roller bearing (2) and special tools to transfer output retainer (3).
  Special Tool
  1. 09922-76140
  2. 09922-76430
  3. 09922-76340
  4. 09922-76150
    NOTE: This installation requires no spacer or oil seal.
    
    Fig 2: Identifying Bevel Pinion Dummy, Rear Taper Roller Bearing And Transfer Output Retainer
    Courtesy of SUZUKI OF AMERICA CORP.
3. Tighten bevel pinion nut (special tool) so that specified bearing preload is obtained.
  NOTE: Before taking measurement, check for rotation by hand more than 15 revolutions.
  
  Tightening torque
  
  Rotational torque of bevel pinion (Bearing preload): 0.50 - 1.30 N.m (0.05 - 0.13 kg-m, 0.35 - 0.95 lb-ft)
  
  Fig 3: Measuring Bearing Preload
  Courtesy of SUZUKI OF AMERICA CORP.
4. Measure height "b" in figure by using vernier caliper.
  Calculate "c" by using measured value.
  
  Height "a" 40 mm Distance "c" = Height "b" - (1.575 in.)
  
  Fig 4: Identifying Transfer Height
  Courtesy of SUZUKI OF AMERICA CORP.
5. Obtain adjusting shim thickness by the following equation.
  Necessary shim thickness "f" = Distance "c" + Distance "d" - 74.0 mm (2.913 in.) Distance "e" 101.95 mm (4.014 in.)
  
  Fig 5: Identifying Shim Thickness Clearance
  Courtesy of SUZUKI OF AMERICA CORP.
6. Select a shim closest to the calculated value (necessary shim thickness) from among the available shims or combine shims to become closest to calculated value.
  For example:
  
  Measure distance "b" is 69.95 mm (2.754 in.).
  
  "c" = 69.95 mm (2.754 in.) - 40.0 mm (1.757 in.) = 29.95 mm (1.179 in.)
  
  "f" = 29.95 mm (1.179 in.) + 74.0 mm (2.913 in.) - 101.95 mm (4.014 in.) = 2.0 mm (0.079 in.)
  
  Calculated thickness of new shim = 2.0 mm (0.079 in.)
  
  Available bevel pinion shim thickness
  
  0.30, 1.85, 1.88, 1.91, 1.94, 1.97, 2.00, 2.03, 2.06, 2.09, 2.12 and 2.15 mm (0.012, 0.072, 0.074,
  
  0.075, 0.076, 0.077, 0.078, 0.079, 0.081, 0.082, 0.083 and 0.084 in.)
Press-fit outer races (front and rear) by using special tool and hydraulic press.
Special Tool

(A): 09913-75520

Fig 6: Pressing-Fit Outer Races
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit front taper roller bearing (1) by using special tool and hydraulic press.
Special Tool

(A): 09925-18011

Fig 7: Pressing-Fit Front Taper Roller Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install bevel pinion with new pinion shaft spacers (1) and new pump seal (2) to transfer output retainer (3).

Fig 8: Identifying Pinion Shaft Spacers And Pump Seal And Transfer Output Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Drive in rear taper roller bearing by using special tool and tapping lightly with plastic hammer.
Special Tool

(A): 09913-84510

Fig 9: Installing Rear Taper Roller Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to new oil seal lip.
"A": Grease 99000-25010SUZUKI Super Grease A
Drive in oil seal (1) by using special tools and hammer.
Special Tool
1. 09940-54910
2. 09913-76010
Transfer output flange oil seal installing depth

"a": 21.0 - 22.0 mm (0.82 - 0.86 in.)

Fig 10: Installing Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Install transfer output flange (1) by tapping with plastic hammer and tighten transfer output flange nut gradually so as rotational torque of bevel pinion to be in specified value.
NOTE:
- If rotational torque of bevel pinion exceeds specification given in the following, replace pinion shaft spacers and tighten flange nut.
- Before taking measurement of rotational torque, rotate pinion over ten rounds in advance.
Bevel pinion bearing preload

: 0.5 - 1.3 N.m (0.05 - 0.13 kgf-m, 0.35 - 0.95 lb-ft)

Special Tool

(A): 09930-40113

Fig 11: Measuring Bevel Pinion Bearing Preload
Courtesy of SUZUKI OF AMERICA CORP.
Caulk transfer output flange nut (1).

Fig 12: Caulking Transfer Output Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.