Rear Differential Disassembly

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Hold differential assembly securely and put identification marks (A) on differential side bearing caps (6).
Take off differential side bearing lock plates (4) and differential side bearing caps (6) by removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear assembly (2) with differential case (3).

Fig 1: Removing Side Bearing Outer Races And Drive Bevel Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.
For H25 engine model, remove drive bevel gear, pinion gear and pinion shaft.
1. With aluminum plates (3) placed on vise first, grip differential case with it and remove bevel gear (2) by removing its bolts (1).
  
  Fig 2: Removing Bevel Gear
  Courtesy of SUZUKI OF AMERICA CORP.
2. There are 8 bolts fastening two differential case halves together. Remove these bolts to separate right-hand case half from left-hand one, and take off right-hand one.
  Special tool
  
  (B): 09930-40113
  
  Fig 3: Separating Differential Case Halves
  Courtesy of SUZUKI OF AMERICA CORP.
3. Remove pinion shaft, side gears, washers, differential pinions, spring washers, thrust washers.
  
  Fig 4: Removing Pinion Shaft, Side Gears, Washers, Differential Pinions, Spring Washers & Thrust Washers
  Courtesy of SUZUKI OF AMERICA CORP.
For H27 engine model, remove drive bevel gear (hypoid gear), differential gears, differential pinions and pinion shafts.
1. 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).
  
  Fig 5: Removing Bevel Gear
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove differential left case (2) from differential right case (1).
  
  Fig 6: Separating Differential Case Halves
  Courtesy of SUZUKI OF AMERICA CORP.
3. Remove pinion shafts, differential gears, washers, differential pinions, spring washers and thrust washers.
  
  Fig 7: Removing Pinion Shafts, Differential Gears, Washers, Differential Pinions, Spring Washers And Thrust Washers
  Courtesy of SUZUKI OF AMERICA CORP.
Using special tools, pull out differential side bearings (1).
Special tool

(C): 09913-85230

(D): 09913-61510

Fig 8: Removing Differential Side Bearings
Courtesy of SUZUKI OF AMERICA CORP.
Remove drive bevel pinion (hypoid gear) assembly.
1. Hold joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2).
  Special tool
  
  (E): 09922-66021
  
  Fig 9: Removing Flange Nut
  Courtesy of SUZUKI OF AMERICA CORP.
2. Make mating marks (1) on drive bevel pinion and companion flange.
  CAUTION: Do not make mating mark on the coupling surface of the flange.
3. Remove companion flange from drive bevel pinion. Use special tool if it is hard to remove.
  Special tool
  
  (F): 09913-65135
  
  Fig 10: Removing Companion Flange From Drive Bevel Pinion
  Courtesy of SUZUKI OF AMERICA CORP.
4. Remove drive bevel pinion with rear bearing, shim and spacer from carrier.
  If it is hard to remove, screw an used nut into drive bevel pinion and hammer on that nut with a plastic hammer but never directly on drive bevel pinion.
  
  Fig 11: Removing Drive Bevel Pinion With Rear Bearing, Shim And Spacer
  Courtesy of SUZUKI OF AMERICA CORP.
5. Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press.
  
  Fig 12: Removing Drive Bevel Pinion Rear Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out front bearing outer race with bearing (2) and oil seal (3).

Fig 13: Driving Out Front Bearing Outer Race With Bearing And Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Drive out rear bearing outer race in the same way as in the Step 6).

Fig 14: Driving Out Rear Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.