Rear Differential Disassembly and Reassembly
Rear Differential Disassembly and Reassembly
Rear Differential Dismounting and Remounting
Disassembly
1) Remove coupling case bolts.
2) Use special tool to separate coupling case (1) from differential carrier (2).
Special Tool
(A): 09912-34510
3) Hold companion flange with special tool and then remove flange nut.
Special Tool
(A): 09930-40113
4) Remove companion flange (1) from pinion.
NOTE:
Use special tool if it is hard to remove.
Special Tool
(A): 09913-65135
5) Use hydraulic press to remove coupling assembly (1).
6) Use special tool to remove oil seal.
Special Tool
(A): 09913-50121
7) Use snap ring pliers to remove snap ring (1).
8) Use special tool and hydraulic press to remove bearing.
Special Tool
(A): 09913-75830
9) Use special tool to remove oil seals from rear differential (1).
NOTE:
It is also possible to remove oil seats after removing differential cover.
Special Tool
(A): 09913-50121
10) Remove differential cover bolts.
11) Use special tool to remove differential cover (1).
Special Tool
(A): 09912-34510
12) Remove differential cover plate from differential carrier.
13) Remove the following parts together from differential carrier (3):
- Differential case
- Differential side right bearing (2)
- Differential side left bearing (1)
- Differential side shim (4)
14) Use special tools to pull out differential side bearings (1).
Special Tool
(A): 09913-60910
(B): 09925-88210
15) First use vise, with aluminum plates (2) placed on it, to grip differential case.
16) Remove bevel gear (hypoid gear) (3).
17) Remove pinion shaft pin with special tool and hammer.
Special Tool
(A): 09922-85811
18) Disassemble differential gears (2), pinions (3), washers and shaft (4) in differential case (1).
19) Remove bevel pinion nut (1) with special tool.
Special Tool
(A): 09927-27910
20) Remove the following parts from differential carrier (4):
- Bevel pinion (1)
- Spacer (2)
- Front bearing (3)
21) Use bearing puller (3) and hydraulic press to remove rear bearing (2) from bevel pinion (1).
22) Remove oil seal from differential carrier.
23) Use hammer and brass bar (1) to remove bearing outer race (front (3) and rear (2)).
Reassembly
NOTE:
Some parts are intended to be replaced as a set. If you replace these parts individually, rather than as a set, performance may be adversely affected.
Always replace the following parts as a set or in an assembly.
- Bevel gear and pinion
- Inner and outer races of a taper roller bearing
1) Use special tools and hydraulic press as shown in figure to press-fit bevel pinion bearing outer races to differential carrier (1).
Special Tool
(A): 09913-85210
(B): 09913-75510
2) Select bevel pinion shim using the following procedures:
a) Apply differential oil to front bearing (2) and rear bearing (1).
b) Install front bearing, rear bearing and special tools (mounting dummy) to differential carrier (3).
NOTE:
Special tools (A) - (D) are included in differential adjuster set (09922-76110).
Special Tool
(A): 09922-76140
(B): 09922-76420
(C): 09922-76330
(D): 09922-76340
(E): 09922-76150
(F): 09922-76530
c) Tighten bevel pinion nut (special tool) so that specified bearing preload is obtained.
Special Tool
(A): 09922-76140
(E): 09922-76150
NOTE:
Before preload measurement with torque wrench, rotate special tool more than 15 revolutions by hand.
Bevel pinion bearing preload (special tool rotational torque)
: 1.3 - 2.6 Nm (0.13 - 0.27 kgf-m, 1.0 - 2.0 lbf-ft) (rotational speed about 50 rpm)
d) Set dial gauge to axle dummy and make 0 (zero) adjustment on surface plate (1).
NOTE:
- When setting dial gauge to mounting dummy (axle dummy), tighten screw lightly. Be careful not to overtighten it as this will cause damage to dial gauge.
- With dial gauge set, turn dummy back and forth by hand a couple of times and attain accurate 0 (zero) adjustment.
- It is desirable to have the short pointer indicate beyond 2 mm when long one is at 0 (zero).
- Special tools (G) - (H) are included in differential adjuster set (09922-76110).
Special Tool
(G): 09922-76250
(H): 09922-76120
(I): 09900-20607
e) Place zero-adjusted axle dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip.
NOTE:
- Repeat turning back and forth of axle dummy and accurately measure distance as far as top surface of pinion dummy.
- When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
f) Dimensional relation of each dummy is as follows. Use the dial gauge reading to calculate the thickness of bevel pinion shim "g" with the formula.
"g" (mm) = "e" - "f"
"e": "a" + "b" + "c" + "d"
- "a": measured value (dial gauge reading)
- "b": special tool (G) radius (31.00 mm (1.220 in.))
- "c": special tool (A) height (40.00 mm (1.575 in.))
- "d": special tool (F) height (9.00 mm (0.345 in.))
"f": bevel pinion mounting distance (80.00 mm (3.150 in.))
g) Select bevel pinion shim that is closest in thickness to "g" (dial gauge reading) in procedure f).
Available bevel pinion shim thickness
3) Install selected shim (1) and rear bearing (2) to bevel pinion (3) using special tools and press.
Special Tool
(A): 09913-85210
(B): 09924-07720
4) Apply differential oil to front bearing and rear bearing.
5) Install bevel pinion (1), new spacer (2) and front bearing (3) to differential carrier (4).
6) Apply grease to new oil seal (2) lip.
"A" Grease: 99000-25011 (SUZUKI Super Grease A)
7) Use a special tool and plastic hammer as shown in figure to install oil seal into differential carrier (1).
Distance between differential carrier and oil seal
"a": 0.5 - 1.5 mm (0.02 - 0.06 in.)
Special Tool
(A): 09913-85210
8) Tighten new bevel pinion nut (1) gradually with special tool to specified torque while turning bevel pinion. Set bearing preload of bevel pinion to specified rotation torque.
NOTE:
The bevel pinion nut is precoated with adhesive. If an overtightened nut is loosened to the specified torque and is used as it is, the nut may loosen.
To tighten the bevel pinion nut, tighten the nut slowly and carefully while measuring the pinion preload, until the specified pinion preload is obtained. Never loosen the nut.
If the nut is overtightened, replace the spacer and nut and then tighten the nut.
NOTE:
- Before taking measurement with torque wrench (2), check for smooth rotation by turning bevel pinion for 15 revolutions or more by hand.
- Measure pinion bearing preload while turning bevel pinion about 50 rpm.
Tightening torque
Bevel pinion nut 230 - 340 Nm (23.5 - 34.7 kgf-m, 170.0 - 251.0 lbf-ft)
Bevel pinion bearing preload (Bevel pinion rotational torque)
: 1.3 - 2.6 Nm (0.13 - 0.27 kgf-m, 1.0 - 2.0 lbf-ft) (rotational speed about 50 rpm)
Special Tool
(A): 09927-27910
9) After applying differential oil to differential gears (4), pinions (5), pinion shaft (3), side washers (1), spring washers (7) and pinion washers (2), install them in differential case (6).
Install side washers and spring washers in correct direction, as shown in figure.
NOTE:
Used left and right differential side washers are not interchangeable.
10) Check pinion (1) for smooth rotation.
11) Align holes of pinion shaft and differential case and install new pinion shaft pin till they are flush with end surface of case.
Special Tool
(A): 09922-85811
12) Measure differential gear (1) thrust play at upper side [A] and lower side [B]. If check result is not as specified, select suitable side washer, replace it and measure differential gear thrust play again.
Differential gear thrust play
: 0.00 - 0.37 mm (0.0 - 0.01 in.)
Available side washer thickness
Special Tool
(A): 09900-20607
(B): 09900-20701
13) Put bevel gear (2) on differential case (3) and tighten them with new bolts (1) to specified torque.
NOTE:
The bevel gear bolts are pre-coated with adhesive. If these bolts are reused, they may work loose.
Be sure to replace the bevel gear bolts with new ones whenever they are removed.
Tightening torque
Bevel gear bolt (a): 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
14) Press-fit differential right side bearing (1) with special tools and hydraulic press.
Special Tool
(A): 09913-80113
(B): 09926-48010
15) Hold differential right side bearing (2) with special tool and press-fit differential left side bearing (1) with special tools and hydraulic press.
NOTE:
Be sure to use bearing holder for the purpose of protecting lower bearing.
Special Tool
(A): 09913-80113
(B): 09926-48010
(C): 09925-88210
16) Select differential side shim using the following procedures:
a) Measure bearings (2) (3) distance "a".
b) Measure distance "b" of bearing retaining position in differential carrier (1).
c) Calculate dimension for selecting shim.
Differential side shim thickness (mm (in.)) = "b" - "a"
d) Select a shim (4) which is close to half the thickness of the calculated value (necessary shim thickness) from among the available shims to install it between the bearing and carrier (3) on the right and left sides.
Available differential side shim thickness
e) Install differential cover without applying sealant to matching surface of differential carrier and differential cover and then tighten differential cover bolts to specified torque.
Tightening torque
Differential cover bolt 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
f) Remove differential cover.
g) To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix bevel pinion and read dial gauge while moving bevel gear.
If bevel gear backlash is out of specification, adjust it by either changing thickness ratio or replacing parts.
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- Measure at least 4 points on bevel gear periphery.
Bevel gear backlash
0.1 - 0.2 mm (0.004 - 0.008 in.)
Special Tool
(A): 09900-20607
(B): 09900-20701
h) As final step, check gear tooth contact as follows:
i) After cleaning 10 bevel gear teeth, paint them with gear marking compound evenly with a brush (1) or sponge etc.
ii) Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact.
iii) Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace if necessary according to instructions in the table.
NOTE:
Be careful not to turn bevel gear more than one full revolution as it will hinder accuracy of check.
NOTE:
If bevel gear backlash and bevel pinion shims are adjusted properly, correct tooth contact should be provided. However, if correct tooth contact is not provided even when they are adjusted properly, there may be an abnormal condition in tooth, differential case or differential carrier. Check each component and replace if necessary.
i) Install differential cover and then tighten differential cover bolts to specified torque.
Tightening torque
Differential cover bolt 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
17) Calculate bevel pinion nut rotational torque. Increase thickness of differential side shim calculated in procedure c) if it is under specification. Decrease thickness of differential side shim calculated in procedure c) if it is over specification. Redo from procedure d).
NOTE:
Before preload measurement with torque wrench, rotate special tool more than 15 revolutions by hand.
Bevel pinion bearing preload (Bevel pinion rotational torque)
: Preload measured in Step 8) +0.3 - 0.7 Nm (3 - 7 kgf-cm, 2.6 - 6.0 lb-in.) (rotational speed about 50 rpm)
18) Remove differential cover and then install differential cover plate.
19) Clean mating surface of differential carrier (1) and differential cover, apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate differential cover with differential carrier, and then tighten bolts to specified torque.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Differential cover bolt 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
20) Use special tool and hydraulic press to install bearing.
Special Tool
(A): 09913-75810
21) Use snap ring pliers to install new snap ring (1).
22) Apply grease to oil seal lip and then use special tool as shown in figure to install oil seals (2) to coupling case (1).
NOTE:
Install oil seal horizontally to surface of coupling case.
"A" Grease: 99000-25011 (SUZUKI Super Grease A)
Distance between case and oil seal "a"
: 1.5 - 2.5 mm (0.06 - 0.10 in.)
Special Tool
(A): 09913-75810
23) Install spacer (1) to coupling assembly (2) as shown in figure.
24) Install grommet (4) of coupling harness into groove (5) of coupling case (3), and then use special tool and hydraulic press (1) to install coupling assembly (2).
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Special Tool
(A): 09913-70123
25) Install companion flange to coupling assembly, and then hold companion flange with special tool and tighten new flange nut to specified torque.
Tightening torque
Flange nut 110 Nm (11.2 kgf-m, 81.5 lbf-ft)
Special Tool
(A): 09930-40113
26) Use special tools and dial gauge to measure runout of companion flange (1) inside diameter.
Mark (2) on companion flange outside diameter where runout is minimum value. If measurement exceeds runout limit, replace companion flange with new one and measure runout again.
Companion flange inside diameter runout limit
: 0.1 mm (0.004 in.)
Special Tool
(A): 09952-06010
(B): 09900-20607
(C): 09900-20701
27) Clean mating surface of differential carrier (1) and coupling case (2), apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate coupling case with differential carrier as shown in figure, and then tighten bolts (5) to specified torque.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Coupling case bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
NOTE:
Install coupling pin (3) by fitting it to groove (4) of coupling case.
28) Apply grease to oil seal lip and then use special tool as shown in figure to install oil seals (1) to rear differential (2).
NOTE:
Install oil seal horizontally to surface of rear differential case.
"A" Grease: 99000-25011 (SUZUKI Super Grease A)
Distance between rear differential and oil seal "a"
: 0.0 - 1.0 mm (0.00 - 0.04 in.)
Special Tool
(A): 09922-59420
