Front Differential Disassembly

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Remove front drive shaft (1) from front drive shaft case (2) by using plastic hammer.

Fig 1: Removing Front Drive Shaft From Front Drive Shaft Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove axle lock actuator motor (1) and front drive shaft case (2) from differential housing (3) by removing bolts (4).

Fig 2: Removing Axle Lock Actuator Motor & Front Drive Shaft Case From Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.
Remove front mounting bracket R (1) from differential housing (2) by removing bolts (3).

Fig 3: Removing Front Mounting Bracket R From Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.
Remove 8 bolts (1, 2) and differential carrier cover for differential carrier.
NOTE: Loosen 8 mm thread diameter bolts (2) first, and then loosen 12 mm thread diameter bolts (1).

Fig 4: Removing Bolts & Differential Carrier Cover
Courtesy of SUZUKI OF AMERICA CORP.
Remove axle lock actuator mounting bolts (1).
Take off differential side bearing outer races (2) and bevel gear with differential case (3).

Fig 5: Removing Differential Side Bearing Outer Races & Bevel Gear With Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Hold universal joint flange with special tool, and then remove flange nut by using socket wrench (2) and power wrench (3).
Special tool
1. (B): 09922-66021
Fig 6: Removing Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.
Make mating marks (1) on pinion and universal joint flange.
CAUTION: Do not make mating mark on the coupling surface of the flange.
Remove universal joint flange from pinion using special tool.
Special tool
1. (C): 09913-65135
Fig 7: Marking & Removing Universal Joint Flange From Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Remove pinion with front bearing and bearing pinion spacer from differential carrier. If it is hard to remove, screw an used nut into pinion and hammer on the nut with a plastic hammer but never directly on pinion.

Fig 8: Removing Pinion With Front Bearing & Bearing Pinion Spacer From Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal and take out rear bearing.
Using special tool, pull out differential side bearings.
Special tool
1. (D): 09913-85230
Fig 9: Removing Differential Side Bearings
Courtesy of SUZUKI OF AMERICA CORP.
With aluminum plates (3) placed on vise first, grip differential case with it and remove bevel gear (2) by removing bolts (1).
CAUTION: Use care not to hold axle lock clutch part with vise. Be sure to hold differential left case.

Fig 10: Removing Bevel Gear
Courtesy of SUZUKI OF AMERICA CORP.
Separate differential case assembly by removing 2 screws (2) and take out free axle hub, differential gears and shims from differential left case (1).

Fig 11: Separating Differential Case Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove front bearing (2) from pinion (1) by using bearing puller (3) and hydraulic press.

Fig 12: Removing Front Bearing From Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Drive out pinion bearing outer races in differential carrier by hammering metal stick applied to them.

Fig 13: Driving Out Pinion Bearing Outer Races In Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.