Disassembly and Reassembly
Rear Differential Assembly Disassembly and Reassembly
Disassembly
1) Drive out rear drive shaft using special tools.
Special Tool
(A): 09942-15511
(B): 09943-17912
2) Remove rear drive right and left retainers.
3) Tapping rear cover flanges with plastic hammer, remove rear cover (1) and dynamic damper (if equipped).
4) Disassembly rear drive right retainer as follows, if necessary.
a) Remove oil seal (1) using special tool.
Special Tool
(A): 09913-50121
b) Remove snap ring.
c) Drive out rear drive shaft bearing using special tools.
Special Tool
(A): 09930-30104
(B): 09941-64511
5) Support differential side left retainer (1) with soft jawed vise and remove oil seal (2) from differential side left retainer using special tool, if necessary.
Special Tool
(A): 09913-50121
6) Take out differential assembly (1), outer race and shim all at once.
7) Pull out differential side bearing (1) using special tools.
Special Tool
(A): 09913-65135
(B): 09925-86010
8) Remove drive bevel gear (hypoid gear), differential gears, differential pinions and pinion shaft as follows.
a) With aluminum plates (2) placed on vise first, grip differential case with it and remove drive bevel gear (hypoid gear) (3) by removing its bolts (1).
b) Remove pinion shafts (1), differential gears, washers, differential pinions, spring washers, thrust washers and pinion joint.
9) Remove drive bevel pinion (hypoid gear) assembly as follows.
a) Hold joint flange (1) with special tool and then remove flange nut and bevel pinion washer.
Special Tool
(A): 09930-40113
b) Make mating marks (1) on drive bevel pinion and companion flange.
NOTE:
Do not make mating mark on the coupling surface of the flange.
c) Remove flange (2) and flange shim from drive bevel pinion. Use special tool if it is hard to remove.
Special Tool
(A): 09913-65135
(B): 09925-88210
d) Remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier.
If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut with a plastic hammer but never directly on drive bevel pinion.
e) Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press.
NOTE:
If the rear bearing is supported on the concave side of the bearing puller, the rear bearing may be damaged.
Be sure to support the rear bearing on the flat side of the bearing puller.
10) Remove oil seal (1) using special tool.
Special Tool
(A): 09913-50121
11) Using a hammer and brass bar (1), drive out front bearing outer race (2).
12) Drive out rear bearing outer race (1) in the same manner as Step 11).
Reassembly
Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described.
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) For press-fitting drive bevel pinion bearing outer races, use special tools and press as shown in the figure.
Special Tool
(A): 09924-74510
(B): 09925-14520
(C): 09913-75510
2) After applying differential oil to differential gear (4), pinions (5), pinion shafts (6), pinion washer, thrust washer (2) and spring washer (1), install them in differential right case (3).
For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.
3) Check differential pinion gear (1) for smooth rotation.
4) Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).
NOTE:
Using bolts other than the specified bolts may cause problems with the front differential.
Use only the specified bolts.
"A" Thread lock cement: 99000-32100 (Thread Lock Cement 1305)
Tightening torque
Bevel gear bolt (a): 200 Nm (20.0 kgf-m, 145.0 lbf-ft)
5) Install special tool to differential case assembly (2) and check differential gear for preload. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special Tool
(B): 09928-06510
Differential gear preload
Max. 2.5 Nm (0.25 kgf-m, 1.8 lbf-ft)
6) Press-fit left side bearing (1) with special tool and hydraulic press.
Special Tool
(A): 09913-75821
(B): 09924-84510-004
7) Press-fit right 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): 09913-75821
(B): 09924-84510-004
(C): 09924-84510-005
8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Special Tool
(A): 09900-20607
(B): 09926-78320
(C): 09951-16070
(D): 09951-46010
(E): 09926-78311-002
(F): 09922-76520
9) Apply differential oil to drive bevel pinion bearings, install special tools with bearings (3) and flange (2) to differential carrier (1).
NOTE:
This installation requires no spacer or oil seal.
Special Tool
(E): 09951-46010
(F): 09926-78311-002
10) Tighten flange nut so that specified bearing preload is obtained.
NOTE:
- Before taking measurement with torque wrench (1), check for rotation by hand and apply small amount of differential oil to bearings.
- On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
Drive bevel pinion bearing preload
0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)
11) Set dial gauge to mounting dummy and make 0 (zero) adjustment on surface plate (1).
NOTE:
- When setting dial gauge to mounting dummy, tighten screw (2) lightly. Be careful not to overtighten it, which will cause damage to dial gauge.
- With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.
- It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).
Special Tool
(A): 09900-20607
(B): 09926-78320
12) Place zero-adjusted mounting dummy and dial gauge set on pinion mounting dummy and take measurement between zero position and extended dial gauge measuring tip.
NOTE:
- Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurately.
- When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
- Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.
Special Tool
(A): 09900-20607
(B): 09926-78311
(D): 09951-16070
(F): 09926-78311-002
09922-76520
13) Obtain adjusting shim thickness by the following equation.
14) Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit rear bearing (1).
Special Tool
(G): 09913-85210
(H): 09940-53111
Available drive bevel pinion adjusting shim thickness
1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21,1.24, 1.27, 1.30 and 0.3 mm
(0.039, 0.040, 0.042, 0.043, 0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)
15) With new pinion spacer (3) inserted as shown in figure, apply differential oil to bearings and then install front bearing (5) and flange shim (6) to differential carrier (4).
NOTE:
Make sure to use new spacer for reinstallation.
16) Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) at specified position as shown in figure. Then apply grease "A" to oil seal lip.
Distance between carrier surface and oil seal
2.5 - 3.5 mm (0.098 - 0.13 in.)
"A" Grease: 99000-25011 (SUZUKI Super Grease A)
Special Tool
(A): 09951-18211
17) Apply grease to both sides of bevel pinion washer. Components
Grease: 99000-25011 (SUZUKI Super Grease A)
18) Apply grease to front bearing contact face of universal joint flange. Components
Grease: 99000-25011 (SUZUKI Super Grease A)
19) While tightening flange nut gradually with special tool, set preload of pinion to specification.
NOTE:
- Before taking measurement with torque wrench (1), check for smooth rotation by hand.
- On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
- Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.
Drive bevel pinion bearing preload
0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.)
Special Tool
(A): 09930-40113
20) Select differential side bearing shim as follows.
a) Measure dimension "a" and "b" using vernier caliper.
b) Calculate dimension "a" - "b", and select shims from among following available size so that total of thickness of right side and left side shims may reach the calculated value.
NOTE:
Select shims so that thickness of right side shims and left side shims become almost even.
Available differential side bearing adjusting shim thickness
Right side: 1.75, 1.85, 1.95, 2.00, 2.05, 2.15 and 2.25 mm (0.069, 0.073, 0.077, 0.079, 0.081, 0.085 and 0.089 in.)
Left side: 2.75, 2.85, 2.95, 3.00, 3.05, 3.15 and 3.25 mm (0.108, 0.112, 0.116, 0.118, 0.120, 0.124 and 0.128 in.)
21) To measure bevel gear backlash, set dial gauge (1) at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear.
Special Tool
(A): 09900-20607
(B): 09900-20701
Bevel gear backlash
: 0.1 - 0.2 mm (0.004 - 0.008 in.)
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- Measure at least 4 points on drive bevel gear periphery.
- If backlash exceeds specification given below, adjust it by changing thickness ratio of differential side bearing shims.
22) Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
23) Install case assembly (1) in carrier (2).
24) As final step, check gear tooth contact as follows.
a) After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
b) Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact.
c) Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table.
NOTE:
Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.
25) Upon completion of gear tooth contact check in Step 22), caulk flange nut (2) with caulking tool (1) and hammer.
26) Clean mating surface of differential carrier (2) and rear cover (1), apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate rear cover with differential carrier, and then tighten bolts to specified torque.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Rear cover bolt No.1 (a): 50 Nm (5.0 kgf-m, 36.5 lbf-ft)
Rear cover bolt No.2 (b): 60 Nm (6.0 kgf-m, 43.5 lbf-ft)
27) Assembly rear drive right retainer as follows.
a) Install rear drive shaft bearing (1) using special tool and press (2).
Special Tool
(A): 09913-75520
b) Install snap ring.
c) Install oil seal using special tools as shown in figure.
Distance between retainer surface and oil seal
"a": 2.7 - 3.0 mm (0.11 - 0.12 in.)
Special Tool
(A): 09924-74510
(B): 09951-16091
28) Apply grease to oil seal lip, and then install oil seal (2) into differential side left retainer (1) at specified position as shown in figure.
Distance between retainer surface and oil seal
"a": 0.65 - 1.65 mm (0.026 - 0.064 in.)
"A" Grease: 99000-25011 (SUZUKI Super Grease A)
Special Tool
(A): 09924-74510
(B): 09926-27610
29) Clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate right retainer with carrier and rear cover, and then tighten bolts to specified torque.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Retainer bolt 50 Nm (5.0 kgf-m, 36.5 lbf-ft)
30) Clean mating surface of left retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate left retainer with carrier and rear cover, and then tighten bolts to specified torque.
"A" Sealant: 99000-31260 (SUZUKI Bond No.1217G)
Tightening torque
Retainer bolt 50 Nm (5.0 kgf-m, 36.5 lbf-ft)
31) Install rear drive shaft using plastic hammer.