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 differential housing (2) by using plastic hammer.

Fig 1: Removing Front Drive Shaft From Differential Housing
Courtesy of SUZUKI OF AMERICA CORP.
Remove 8 bolts (1) for fastening differential carrier (2 of which are reamer bolts (2)) and then take differential assembly out of housing.

Fig 2: Removing Differential Carrier From Housing
Courtesy of SUZUKI OF AMERICA CORP.
Set special tool on vise (1) securely.
Special tool
1. (A): 09944-76010
Fig 3: Setting Special Tool On Vise
Courtesy of SUZUKI OF AMERICA CORP.
Using 4 bolt and nut sets, set differential assembly onto differential carrier holder and put identification marks ("A") on differential side bearing caps (6).
Remove differential inner hose and actuator bracket bolt.
Take off differential side bearing lock plates (4) and differential side bearing caps (6) removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear with differential case (3).
Turn differential assembly together with special tool by 90 degrees and grip it with vise again.
Special tool
1. (A): 09944-76010
Remove air inlet union (2) from differential carrier (1).

Fig 4: Removing Air Inlet Union From Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Hold universal joint flange with special tool and then remove flange nut by using power wrench.
Special tool
1. (B): 09922-66021
Fig 5: Holding Universal Joint Flange With Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Make mating marks (1) on drive bevel pinion and companion flange.
CAUTION: Do not make mating mark on the coupling surface of the flange.
Remove companion flange from pinion. Use special tool if it is hard to remove.
Special tool
1. (C): 09913-65135
Fig 6: Removing Companion Flange From Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Remove bevel pinion with front bearing, and spacer from carrier.
If it is hard to remove, screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on pinion.

Fig 7: Removing Bevel Pinion With Front Bearing & Spacer From Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Using special tools, pull out differential side bearings.
Special tool
1. (D): 09913-85230
Fig 8: Pulling Out 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 its 10 bolts (1).
CAUTION: Use care not to hold axle lock clutch part with vise. Be sure to hold differential left case.

Fig 9: Removing Bevel Gear
Courtesy of SUZUKI OF AMERICA CORP.
Separate differential case assembly by removing 2 screws (2) and take out free axle hub, side gears and shims from differential left case (1).

Fig 10: Separating Differential Case Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove bevel pinion front bearing (2) by using bearing puller (3) and hydraulic press.

Fig 11: Removing Bevel Pinion Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Drive out bevel pinion bearing outer races in differential carrier by hammering metal stick applied to them.

Fig 12: Removing Bevel Pinion Bearing Outer Races From Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.