Suzuki Swift Sport 2004 Service & Repair Manual page 848

5B-34 Manual Transmission/Transaxle:
Assembly
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly. Make sure that all parts are clean.
1) Assemble differential gear and measure thrust play
of differential gear as follows.
Special tool
(A): 09900–20607
(B): 09900–20701
Differential gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)
Left side
1. Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to top
surface of gear (2).
2. Using 2 screwdrivers (1), move gear up and
down and read movement of dial gauge pointer.
Right side
1. Using similar procedure to the left side, set dial
gauge tip to gear (2) shoulder.
2. Move gear up and down by hand and read dial
gauge.
2) If thrust play is out of specification, select suitable
thrust washer from among the following available
size, install it and check again that specified gear
play is obtained.
Available thrust washer thickness
0.85 mm (0.033 in.)
0.90 mm (0.035 in.)
0.95 mm (0.037 in.)
1.00 mm (0.039 in.)
1.05 mm (0.041 in.)
1.10 mm (0.043 in.)
1.15 mm (0.045 in.)
[A]: Left side
3) Drive in new differential pinion shaft pin (2) till the
depth from differential case (3) surface is about 1
mm (0.04 in.).
4) Press-fit left bearing (2) using special tool and
copper hammer.
Special tool
(A): 09913–76010
5) Support differential assembly (1) as illustrated so as
to left bearing is floating, and then press-fit right
bearing (3) using special tools.
Special tool
(A): 09913–76010
(B): 09951–16060
3
2
I3RH0A520083-01
[B]: Right side
(A)
1
(B)
I6RS0C520008-01