Differential Case Assembly

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.

Install differential gears (3), free axle hub (4) and washers (2) to left case (7).
Install left case to right case (1) and tighten screws (8).

Fig 1: Installing Differential Case Components
Courtesy of SUZUKI OF AMERICA CORP.
Put bevel gear (1) on differential case (2) and fasten them with 10 bolts (3) by tightening them to specified torque. Use thread lock cement for 10 bolts (3).
CAUTION: Use of any other bolts than that specified is prohibited.
1. "A": Thread lock cement 99000-32020
Tightening torque
1. Drive bevel gear bolt (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)
Fig 2: Installing Bevel Gear On Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit side bearing (1) with special tool and hydraulic press.
Special tool
1. (G): 09944-66020
Fig 3: Press-Fitting Side Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install actuator (1) to differential case (2).
NOTE: Note that installing direction is as shown in the figure.

Fig 4: Installing Actuator To Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Hold bearing press-fitted in Step 7 with holder and press-fit side bearing on the other side.
NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.

Special tool
1. (G): 09944-66020
2. (H): 09951-16060
Fig 5: Press-Fitting Side Bearing
Courtesy of SUZUKI OF AMERICA CORP.