Rear Differential Disassembly and Reassembly
Rear Differential Disassembly and ReassemblyDisassembly
1. Remove rear mounting bracket from rear differential.
2. Remove drive shaft flanges.
3. Separate coupling case from differential carrier using special tool.
Special Tool: 0991234510
4. Hold companion flange with special tool and then remove flange nut.
Special Tool A): 09930-40113
5. Remove companion flange (1) from pinion. Use special tool if it is hard to remove.
Special Tool (A): 09913-65135
6. Remove coupling assembly (1) by using hydraulic press.
CAUTION: Do not drop coupling assembly. If it is dropped, replace it with a new one.
7. Disassemble coupling case as follows, if necessary.
a) Remove oil seal using special tool.
Special Tool (A): 09913-50121
b) Remove snap ring using snap ring pliers.
c) Remove bearing using special tool and hydraulic press.
Special Tool (A): 09913-75830
8. Remove oil seals from rear differential (1) using special tool.
Special Tool (A): 09913-50121
9. Remove differential cover (1) using special tool, and then take out differential assembly, outer race and shim all at once.
Special Tool (A): 09912-34510
10. Pull out differential side bearings (1) using special tools.
Special Tool
(A): 09913-60910
(B): 09925-88210
11. 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) Drive out differential side pinion shaft pin with special tool and hammer.
Special Tool (B): 09922-85811
c) Disassemble differential gears (2), pinions (3), washers and shaft (4) in differential case (1).
12. Remove bevel pinion nut with special tool.
Special Tool (A): 09927-27910
13. Remove rear bearing (2) from drive bevel pinion (1) by using bearing puller (3) and hydraulic press.
14. Using a hammer and brass bar (1), drive out front bearing outer race (2).
15. Using a hammer and brass bar (1), drive out rear bearing outer race (2).
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 in the following.
CAUTION:
^ Bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
^ When replacing taper roller bearing, replace as inner race & outer race assembly.
1. Press-fit bevel pinion bearing outer races to differential carrier (1) by using special tools and hydraulic press as shown in the figure.
Special Tool
(A): 09913-85210
(B): 09913-75510
2. 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). For correct installing direction of side washers and spring washers, refer to figure.
NOTE: Used left and right differential side washers are not interchangeable.
3. Check pinion gear (1) for smooth rotation.
4. Align holes of pinion shaft and differential case and drive in differential pinion shaft pin till they are flush with end surface of case.
Special Tool (A): 09922-85811
5. Put bevel gear (2) on differential case (3) and tighten new bolts (1) to specified torque.
CAUTION: Use of any other bolts than that specified is prohibited.
Tightening torque
Bevel gear bolt a: 73 Nm (7.3 kgf-m, 52.0 ft. lbs.)
6. Press-fit differential right side bearing (1) with special tools and hydraulic press.
Special Tool
(A): 09913-80113
(B): 09926-48010
7. 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
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): 09922-76120
(B): 09922-76250
(C): 09922-76140
(D): 09922-76420
(E): 09922-76330
(F): 09922-76150
(G): 09922-76340
(H): 09922-76530
9. Set special tools and make drive bevel pinion mounting dummy.
Special Tool
(A): 09922-76120
(B): 09922-76250
10. Install dial gauge (1) to mounting dummy as shown in figure.
Special tool set distance
"a": 38.0 mm (1.496 in.)
"b": 0 mm (0.000 in.)
11. Set special tools and make drive bevel pinion dummy.
Special Tool
(A): 09922-76140
(B): 09922-76420
(C): 09922-76330
(D): 09922-76340
12. Apply gear oil to drive bevel pinion bearings, install special tools with bearings to differential carrier as shown in figure.
Special Tool
(A): 09922-76140
(B): 09922-76420
(C): 09922-76330
(D): 09922-76340
(E): 09922-76150
(F): 09922-76530
NOTE: This installation requires no spacer or oil seal.
13. Tighten bevel pinion nut (special tool) (1) so that specified bearing preload is obtained.
NOTE: Before taking measurement, check for rotation by hand more than 15 revolutions.
Pinion bearing preload (at 50 r/min): 1.3 - 2.6 Nm (13.0 - 26.0 kgf-cm, 11.3 - 22.6 lb-in.)
14. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate.
NOTE:
^ When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which 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 that short pointer indicates beyond 2 mm when long one is at 0 (zero).
15. Place zero-adjusted mounting dummy (1) and dial gauge set on pinion dummy (2) and take measurement between zero position and extended dial gauge measuring tip.
NOTE:
^ Repeat turning back and forth 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.
Necessary shim thickness "e" = Dial gauge measured value "c"
16. Necessary adjusting shim thickness is the same value as measured value by dial gauge.
17. Select adjusting shim(s) (2) closest to obtained value from among the following available sizes and put it in place and then press-fit rear bearing (1) to bevel pinion (3).
Available shim thickness: 0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81, 0.84 and 0.87 mm (0.012, 0.023, 0.024, 0.026, 0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034 in.)
Special Tool (D): 09925-18011
18. With new pinion spacer (2) inserted as shown in figure, install front bearing (1) to differential carrier (3).
NOTE: Apply differential oil to front and rear bearings.
19. Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) as shown in figure. Then apply grease to oil seal lip.
NOTE: Install oil seal horizontally to surface of differential carrier.
"A": Grease 99000-25010SUZUKI Super Grease A
Distance between differential carrier and oil seal "a": 0.5 - 1.5 mm (0.02 - 0.06 in.)
Special Tool (A): 09913-85210
20. Tighten bevel pinion nut (1) gradually with special tool to specified torque while turning bevel pinion. Set bearing preload of bevel pinion to specification.
NOTE:
^ Before taking measurement with torque wrench, check for smooth rotation with turning bevel pinion 15 revolutions or more by hand.
^ Be sure to tighten gradually and carefully till specified pinion bearing preload is obtained. Turning back overtightened flange nuts should be avoided.
^ Measure pinion bearing preload while turning bevel pinion about 50 rpm.
^ Write down measured value of bevel pinion bearing preload for differential side bearing shim adjustment.
Special Tool (A): 09927-27910
Tightening torque
Bevel pinion nut: 230 - 340 Nm (23.0 - 34.0 kgf-m, 166.5 - 246.0 ft. lbs.)
Bevel pinion bearing preload (Bevel pinion rotational torque): 1.3 - 2.6 Nm (13.0 - 26.0 kgf-cm, 11.3 - 22.6 lb-in.)
21. Install differential case assembly, bearing outer races, removed shim and differential cover, temporarily.
NOTE:
^ Used left and right outer races are not interchangeable.
^ When measuring bevel pinion bearing preload, install differential cover with sealant not applied.
22. Select differential side bearing shim so that bevel pinion bearing preload may be specified value.
NOTE: Select shims so that thickness of right side shims and left side shims become almost even.
Bevel pinion bearing preload
Preload measured in Step 20) + 0.3 - 0.7 Nm (3 - 7 kgf-cm, 2.6 - 6.0 lb-in.)
Available shim thickness: 0.45, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65 and 2.70 mm (0.017, 0.090, 0.092, 0.094, 0.096, 0.098, 0.100, 0.102, 0.104 and 0.106 in.)
23. Remove differential cover.
24. To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. If bevel gear backlash is out of specification, repeat Step 22).
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.
Drive bevel gear back lash: 0.1 - 0.2 mm (0.004 - 0.008 in.)
Special Tool
(A): 09900-20607
(B): 09900-20701
25. 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.
26. 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 99000-31260SUZUKI Bond No.1217G
Tightening torque
Differential cover bolt: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
27. Assemble coupling case as follows.
a) Install bearing using special tool and hydraulic press.
Special Tool (A): 09913-75830
b) Install snap ring using snap ring pliers.
c) Apply grease to oil seal lip, install oil seal (2) to coupling case (1) using special tool as shown in figure.
NOTE: Install oil seal horizontally to surface of coupling case.
"A": Grease 99000-25010SUZUKI 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
28. Install spacer (1) to coupling assembly (2) as shown in figure.
29. Install grommet of coupling harness into groove of coupling case and then install coupling assembly by using hydraulic press.
30. Install companion flange to pinion, and then hold companion flange with special tool and tighten flange nut.
Tightening torque
Flange nut: 110 Nm (11.0 kgf-m, 79.5 ft. lbs.)
Special Tool (A): 09930-40113
31. 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 to specified torque.
"A": Sealant 99000-31260SUZUKI Bond No.1217G
Tightening torque
Coupling case bolt a: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
NOTE: Install coupling pin (3) by fitting it to groove (4) of coupling case.
32. Apply grease to oil seal lip, and then install oil seals (1) to rear differential (2) using special tool as shown in figure.
NOTE: Install oil seal horizontally to surface of rear differential case.
"A": Grease 99000-25010SUZUKI Super Grease A
Distance between rear differential and oil seal "a": 1.0 - 2.0 mm (0.04 - 0.08 in.)
Special Tool (A): 09913-75810
33. Install drive shaft flange.
34. Install rear mounting bracket to rear differential.