[swifty_ano]

So like many other vitara owners. I have become victim to the paper thin alloy diff.
Now I know diffs are best left to the proffessionals. But to be honest, I'm an absolute tight ass.

I understand that sometimes there are issues with people doing it themselves. Can anyone tell me what the main problems are and how they are to be prevented.

I would appreciate pro's and con's on DIY. But please speak from an experienced background. Not just because your uncles mate said it was a bad idea.

From what I can gather, you can adjust the backlash from the amount of turns you tighten with that locking ring. With fitting a different ring and pinion from another diff, I pressume the old settings would be irrelevant due to machining differences.
So what is the process of resetting it with the correct tolerances.

Now this thread is to educate me and hopefully others to make an educated decision before jumping into it.

[Rusho]

I'm no expert on the assembly of diff centre's. But for me the set up of one is a precise beast that you should not take a chance on. Back lash is set via a guage to get it precise, most other tolerances need to be pretty spot on also. The kind of quality a back yard bench job doesn't really get you Do the job properly and do it once. The money spent now will probably save you later on, and perhaps save you being standard somewhere.

Just my thoughts though

[royce]

back lash is nothing to setup, which is why you should send it to a shop

you need to set the pinion height correctly, to do this you either need a special Suzuki tool to pre measure the housing and get the right shims straight up, or you need to assemble the pinion into teh housing, set the bearing preload, assemble the hemisphere into the housing, set the backlash and bearing preload, paint the gears and check the pattern, then if its not spot on pull it all apart again, change a shim to something you think might be better and try again.

not to mention having the tools to set the bearing preload correctly as well

Sure you might get it close, but youll never get it right, if you are ok with it maybe being noisy and not living as long as it could go for it, I would never do my own

[neofitou]

swifty_ano wrote:

From what I can gather, you can adjust the backlash from the amount of turns you tighten with that locking ring. With fitting a different ring and pinion from another diff, I pressume the old settings would be irrelevant due to machining differences.

Yes, this only works if you are using all the same stuff, for example putting in an auto locker or spool.

swifty_ano wrote:

So what is the process of resetting it with the correct tolerances.

The correct procedure and tollerances is in the FSM, but basically you set the pinion depth first with shims (probably not needed) then the bearing preload, and then backlash using a feeler guage, paint the gears and make sure the contact patch is in the middle of the ring gears.

Like Royce said you need the tools to do it properly.

[Buddies72]

I've rebuilt numerous diffs over the years with mixed results.

Setting up a new pinion/carrier is painful if you don't have all the specialist gear that Royce mentioned above

Bearing preload on the pinion is difficult to get right even with the right tools, and you only get one crack at this due to the crush sleeve setup in the suzuki diffs.

I built my GV steel diff myself with 5.12s figuring it was only the front diff and wasn't going to prevent me getting home. In saying that I've done a few before and had access to most of the correct gear to get it done.

In short, if you can at all afford it, take it to a pro who has been recommended to you, you won't regret the expense.

If you can't afford it or just want to do it yourself, be prepared to write off every $$$ you put into the diff, as diffs rarely go bang without destroying themselves completely.

[swifty_ano]

Ok, so what do I need.

If I drop the my GV centre at the mechanics. Include my 5.12 centre and airlocker.
He will be right. I don't need to buy anymore?

[royce]

the carrier part of the GV center

the ring and pinion and pinion nut

the drive flange

a rebuild kit

an airlocker

Should do it, dont give it to a mechanic, take it to a diff shop