Suzuki Automatic Positive-Locking Differential PDF Installation Manual

Welcome to the growing family of LOCK-RIGHT owners! This manual will help you install your new LOCK-RIGHT automatic 100% full-locking differential. When the installation is complete, your vehicle will have extreme traction! We trust that you will be pleased with its performance and thank you for your confidence in our products. LOCK-RIGHT installation simply involves disassembling and re-assembling the differential case, replacing a few parts in the process. These instructions are detailed to the point that a person who is reasonably familiar with automotive work can install a LOCK-RIGHT into a third member in about three to four hours; please read them carefully before you start to be sure that you thoroughly understand them. Do not attempt shortcuts unless you know exactly what you are doing. These instructions also assume that you have the proper shop manual for reference to instructions about axle removal,

torque values, settings, clearances, etc. that apply to your particular vehicle. Our manual is a general guide to operations but does not contain specific information for each vehicle. We suggest that your first installation be done in the rear axle. The weight of the engine over the front axle is reduced by weight transfer to the rear as your vehicle climbs a hill, meaning that more and more weight is being applied to the rear axle, where the locker is located, as more traction is needed. Remember: This instruction manual is provided for your convenience to assist you or your mechanic with the installation of your new LOCK-RIGHT. However, the ultimate responsibility for the success of your installation and the subsequent proper operation of your vehicle rest with you, the vehicle owner. When your installation is complete, you will have a vehicle with significantly increased capabilities that will be hard to believe. For continued “fun in the sun,” operate it in a safe and responsible manner. Be sure to read and understand the driving information in the LOCK-RIGHT Vehicle Owner’s Manual! Background Information The differential case is the round housing inside the rear axle assembly to which the ring gear is bolted and which contains the differential spider and side gear assembly. It is installed in the differential carrier, which is the housing that holds the case, drive pinion gear, bearings, etc.

The carrier may be removable (as part of a “drop-out” unit, or third member), or it may be integral (as a permanent part of the axle assembly, mounted in the vehicle). This manual covers the removable third member, technically known as the Differential and Carrier Assembly. The LOCK-RIGHT is designed to fit into standard open differential cases only, not into limited-slip (clutch-pack) type cases. If your vehicle contains a limited-slip unit you will need to purchase a standard open differential, thrust washers and pinion shaft before proceeding. A word about Pinion shafts: Some models of differential use shafts with circumferential oil grooves for oil diftribution, while others use shafts with flsts. The shafts withe flats are re-used, while those with gooves are not. If new shafts are provided in your kit, use them. If no shafts are provided, use the existing shafts. A word about side gear thrust washers: All differentials originally had a thrust washer under each side gear. Thrust washers are large in diameter and between about 1/32-inch (.031, or 0, 76-mm) and 1/16-inch (.062, or 1,52-mm) thick. If either one or both are missing from the original differential, obtain new one(s) before proceeding! The LOCK-RIGHT is designed to be used with a correct thrust washer under each coupler, and failure to use this washer is easy to observe during inspection and will void the warranty. NOTE: The parts shown in the various figures are typical and may not exactly depict your particular model. LOCK-RIGHT Installations Covered in This Manual Removable third member axles. Typical of these are all rear and some front axles in various models of Suzuki 4×4 vehicles.

The LOCK-RIGHT is designed to function in 4-pinion differentials only, not in 2-pinion design; to install a LOCK- RIGHT in these differentials a suitable 4-pinion rear differential may be substituted. Preliminary Steps The following steps are only a general guide to preliminary operations used for preparing your vehicle for LOCK-RIGHT installation. For detailed information, refer to your shop manual. In general, the preliminary steps include: a) Blocking the vehicle, putting transmission in neutral b) Loosening the wheel lug nuts (tire removal may be optional; see shop manual) c) Jacking up the axle; securely resting it on jack stands; d) Removing the tires (some axles) e) Disconnecting the brake lines and emergency brake cables (some axles) f) Pulling out one or both axles a few inches. Removal and Disassembly Summary of steps in this section: a) Securely block and jack up vehicle b) Pull out axle shafts by about six inches c) Remove third member from vehicle d) Observe ring gear backlash e) Mark bearing caps and adjusters f) Remove differential case from carrier g) Mark bearing races h) Remove ring gear i) Remove internal parts j) Install LOCK-RIGHT. Removal of the Differential Case from the Carrier 1. Remove the third member from the vehicle as described in the shop manual. Follow all safety precautions. 2. Check to be sure that the third member is in good condition and that nothing is loose, worn or scored. Rock the ring gear back and forth to get a “feel” for the backlash and check to see that it appears to be set up properly. If any out-of- spec conditions exist, be sure to correct them before subsequent re-assembly.

NOTE: The third member itself can be disassembled and re-assembled without changing the ring and pinion settings if you are careful. Follow these steps in detail. 3. Mark everything! Don’t touch a bolt until you have done so. The easiest tool to use is a center punch. We suggest placing the whole assembly upright (the same position as when in the vehicle), looking at the ring gear end. Mark the carrier and bearing cap on the ring gear side with one punch mark and on the other side with two marks (Figure 2). The caps are not interchangeable! Also mark each bearing adjuster directly under the lock with this same mark to note its side and rotational position. This mark is very important to correct re-assembly! 4. Remove the adjuster locks. (See Figure 3). Be sure that each adjuster is marked at the lock with the correct number of punch marks for each side. The adjusters are not interchangeable after they are marked for position! (In general, the adjuster locks themselves are interchangeable.) 5. Remove the bearing caps (Figure 3). 6. Slide (tap) the adjuster up and out and remove the bearing race on the ring gear side first and put a very small grind mark on the outside of the race to mark it. Scraping it on a cement floor also works, or you can use a tag. Be sure that you can identify it for proper re-assembly on the correct side!

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