Transfer Output Retainer Assembly Disassembly and Reassembly: Reassembly

1. Install front taper roller bearing (1) to bevel pinion dummy (special tools).

   Special Tool 

   1. 09922-76140 
   2. 09922-76430 
      Fig 1: Installing Front Taper Roller Bearing To Bevel Pinion Dummy

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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. 09922-76420 
   3. 09922-76340 
   4. 09922-76150 
   NOTE: This installation requires no spacer or oil seal.
   Fig 2: Installing Bevel Pinion Dummy And Rear Taper Roller Bearing

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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.

   Rotational torque of bevel pinion (Bearing preload) 

   0.50 - 1.30 N.m (0.05 - 0.13 kgf-m, 0.35 - 0.95 lbf-ft) 

   Fig 3: Checking Rotational Torque Of Bevel Pinion (Bearing Preload)

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4. Measure height "b" in figure by using vernier caliper.

   Calculate "c" by using measured value.

   HEIGHT SPECIFICATIONS
   
   

   Distance "c" = Height "b" - Height "a" 40 mm (1.575 in.)

   Fig 4: Identifying Height And Distance

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5. Obtain adjusting shim thickness by the following equation.
   SHIM THICKNESS SPECIFICATIONS
   
   

   Necessary shim thickness "f" = Distance "c" + Distance "d" - Distance "e" 74.0 mm (2.913 in.) 101.95 mm (4.014 in.)

   Fig 5: Identifying Shim Thickness Dimensions

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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.) 

Special Tool 

(A): 09913-75520 

Fig 6: Fitting Outer Races (Front And Rear) Using Special Tool

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Special Tool 

(A): 09925-18011 

Fig 7: Fitting Front Taper Roller Bearing Using Special Tool

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Special Tool 

(A): 09913-84510 

Fig 9: Driving In Rear Taper Roller Bearing By Using Special Tool

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"A": Grease 99000-25011 (SUZUKI Super Grease A) 

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: Checking Transfer Output Flange Oil Seal Installing Depth

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Bevel pinion bearing preload 

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

Special Tool 

(A): 09930-40113 

Fig 11: Checking Bevel Pinion Bearing Preload

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