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Home >> Suzuki >> 2004 >> Aerio S, Standard >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Repair Instructions >> Differential Case
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Differential Case

  1. After applying differential oil to side gears (4), pinions (5), pinion shaft (3), side washers (1) and pinion washers (2), install them in differential case (6).
    NOTE: Used left and right differential side washers are not interchangeable.
    Fig 1: Installing Pinions, Pinion Shaft, Side Washers & Pinion Washers
    G00784067Courtesy of SUZUKI OF AMERICA CORP.
  2. Check pinion gear (1) for smooth rotation.
    Fig 2: Checking Pinion Gear For Smooth Rotation
    G00784068Courtesy of SUZUKI OF AMERICA CORP.
  3. Align pinion shaft hole position with differential case and drive in differential pinion shaft pin till they are flush with end surface of case.

    Special tool 

    (A): 09922-85811

    Fig 3: Aligning Pinion Shaft Hole Position With Differential Case
    G00784069Courtesy of SUZUKI OF AMERICA CORP.
  4. Apply thread lock cement to thread of bevel gear bolts (1).
  5. Put bevel gear (2) on differential case (3) and fasten them with 8 bolts (1) by tightening them to specified torque.
    CAUTION: Use of any other bolts than that specified is prohibited.

    "A": Thread lock cement 99000-32110 

    Tightening torque 

    Bevel gear bolts (a): 73 N.m (7.3 kg-m, 52.0 Ft.Lbs.)

    Fig 4: Tightening Bevel Gear Bolts
    G00784070Courtesy of SUZUKI OF AMERICA CORP.