Category: Suzuki Tracker 1991 Repair Ser

Replacing the differential pinion bearing on a Suzuki Tracker is a task that requires precision, patience, and the right tools. Let’s dive into the details of the process step-by-step.

### Tools and Materials Needed

1. **Basic Hand Tools:**
– **Socket Set:** A complete set of metric sockets (including 10mm to 22mm) for various bolts and nuts.
– **Ratchet Wrench:** A 3/8” drive ratchet is typically sufficient for most fasteners in the differential assembly.
– **Torque Wrench:** Essential for ensuring bolts are tightened to the manufacturer’s specifications, usually in foot-pounds (ft-lb) or Newton-meters (Nm).
– **Breaker Bar:** A longer handle that provides extra leverage for loosening stubborn nuts and bolts.
– **Pliers:** Needle-nose pliers can be helpful for removing small clips or retaining rings.

2. **Specialized Tools:**
– **Differential Bearing Puller:** A specialized tool designed to safely remove bearings without damaging the housing or surrounding components.
– **Pinion Depth Gauge:** This tool is crucial for measuring the depth of the pinion Gear to ensure proper alignment during reassembly.
– **Dial Indicator:** Used to measure the backlash between the ring and pinion gears, ensuring that they mesh correctly.
– **Slide Hammer:** This tool can assist in removing stubborn components, especially when dealing with the pinion bearing.

3. **Consumables:**
– **New Pinion Bearings:** Make sure to get high-quality replacements that match the specifications for your Suzuki Tracker.
– **Differential Oil:** You will need fresh differential oil to refill the assembly after the repair.
– **Sealant or Gasket:** Depending on your model, you may need a new gasket or sealant to ensure a proper seal during reassembly.
– **Cleaning Solvent:** To clean the differential casing and other components before reassembly.

### Step-by-Step Procedure

#### Step 1: Preparation

1. **Safety First:** Before you begin, make sure the vehicle is parked on a level surface. Engage the parking brake and wear safety goggles and gloves to protect yourself from debris and sharp edges.

2. **Disconnect the Battery:** This is a good practice to ensure that you won’t accidentally activate any electrical components during your repair.

#### Step 2: Remove the differential Cover

1. **Jack Up the Vehicle:** Use a hydraulic jack to lift the rear of the vehicle and secure it on jack stands to ensure stability.

2. **Remove Rear Wheels:** Using your socket set, remove the lug nuts and take off the rear wheels to give you better access to the differential.

3. **Drain differential Fluid:** place a drain pan under the differential cover. Remove the cover bolts using your ratchet and socket, and gently pry the cover off. Allow the fluid to drain completely.

#### Step 3: Remove the Pinion Gear

1. **Mark the Position:** Before you remove the pinion, it’s crucial to mark the position of the pinion nut and the yoke. This ensures that you can reassemble it in the same position to maintain the original settings. You can use a marker or a scribe for this.

2. **Remove the Pinion Nut:** Use a breaker bar and a socket to loosen and remove the pinion nut. Be cautious, as it may be tightly secured.

3. **Extract the Yoke:** Once the nut is removed, use a slide hammer or a gentle tapping method to pull off the yoke. Be careful not to damage the threads on the pinion shaft.

#### Step 4: Remove the Old Pinion Bearings

1. **Bearing Puller Setup:** Attach the differential bearing puller to the pinion bearing. Ensure it is securely fastened to prevent slipping during the removal process.

2. **Remove the Bearing:** Using the puller, apply even pressure to extract the bearing from the pinion shaft. If it’s stuck, you may need to apply some heat to the housing (not the bearing itself) to expand the metal slightly, which can help in loosening the bearing.

3. **Clean the Area:** Once the bearing is removed, clean the pinion shaft and housing thoroughly with a cleaning solvent to remove any debris or old lubricant.

#### Step 5: Install New Pinion Bearings

1. **Prepare the New Bearing:** Before installation, ensure that the new bearing is properly lubricated with differential oil. This helps with the initial operation and longevity of the bearing.

2. **Press the New Bearing On:** Using the bearing press tool, carefully press the new bearing onto the pinion shaft. It’s essential to apply even pressure to avoid damaging the bearing.

#### Step 6: Reassemble the Differential

1. **Reinstall the Yoke:** Position the yoke back onto the pinion shaft, aligning it with the marks you made earlier. Secure it with the pinion nut, tightening it to the specifications in your service manual using a torque wrench.

2. **Check the Pinion Depth:** Using the pinion depth gauge, measure to ensure the new bearing is installed at the correct depth. Adjust if necessary.

3. **Set the Backlash:** Install the dial indicator on the ring Gear and measure the backlash. Adjust as needed by shimming the carrier if it’s too tight or too loose.

4. **Reinstall the differential Cover:** Apply sealant or install a new gasket on the cover, then bolt it back into place. Make sure to torque the bolts to specification.

#### Step 7: Refill with differential Oil

1. **Refill the Differential:** Locate the fill plug on the differential and remove it. Using a funnel, refill the differential with the appropriate type and amount of Gear oil as specified in your owner’s manual.

2. **Replace Wheels and Lower Vehicle:** Reinstall the rear wheels, lower the vehicle from the jack stands, and reconnect the battery.

#### Step 8: Test Drive

1. **Check for Leaks:** After completing the job, it’s wise to run the vehicle for a short distance and check for any leaks around the differential cover and pinion seal.

2. **Final Inspection:** Listen for any unusual noises during your test drive. If everything sounds normal, you’ve successfully replaced the differential pinion bearing on your Suzuki Tracker!

### Conclusion

Replacing the differential pinion bearing is a meticulous process that can significantly improve the performance and longevity of your vehicle’s drivetrain. By following these detailed steps and using the right tools, you ensure a successful repair. Remember, if at any point you feel uncertain or unsupported, seeking assistance from a professional mechanic is always a sensible option. Happy wrenching!
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Download Suzuki Tracker 1991 Repair Service Manual –

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