LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2006 >> Aerio Base, AWD >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Differential >> Repair Instruction >> Rear Differential Disassembly and Assembly >> Differential Unit
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Differential Unit

  1. Install side oil seal to bearing outer race (1).

    Then apply grease to oil seal lip.

    : Grease 99000-25010 

    Special Tool 

    1. 09913-75520 
      Fig 1: Installing Side Oil Seal To Bearing Outer Race
      G04590364Courtesy of SUZUKI OF AMERICA CORP.
  2. Place bearing outer races (1) on their respective bearings.
    NOTE: Used left and right outer races are not interchangeable.
  3. After applying differential oil to side bearings, install case assembly (2) in differential carrier (3).
    Fig 2: Installing Case Assembly In Differential Carrier
    G04590365Courtesy of SUZUKI OF AMERICA CORP.
  4. Tighten bearing retainer.

    Special Tool 

    1. (B): 09923-58520 
      Fig 3: Tightening Bearing Retainer
      G04590366Courtesy of SUZUKI OF AMERICA CORP.
  5. To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion, tighten both retainers and read dial gauge while moving bevel gear.
    NOTE:
    • Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
    • As a practical measure following would be recommended to obtain specified backlash and side bearing preload at the same time.
      • Obtain specified backlash by turning both retainers inward lightly.
      • Tighten both retainers further by one notch at a time.
    • Measure at least 4 points on drive bevel gear periphery.

    Special Tool 

    (C): 09900-20606 

    : 09923-58520 

    : 09900-20701 

    Drive bevel gear backlash 

    Standard: 0.1 - 0.2 mm (0.004 - 0.008 in.) 

    Fig 4: Measuring Bevel Gear Backlash
    G04590367Courtesy of SUZUKI OF AMERICA CORP.
  6. With bevel gear installed, measure rotational torque while turning bevel pinion about 50 RPM by using special tool.

    Special Tool 

    1. (E): 09922-75222 

      Differential side bearing preload: 

      (Measured bevel pinion bearing preload) + (3 - 5 kg-cm (2.6 - 4.3 lb-in)) 

      Rotational force with special tool: 

      (Measured bevel pinion rotational force) + (0.6 - 1 kg (1.3 - 2.2 lb)) 

      Fig 5: Measuring Bevel Pinion Rotational Force
      G04590368Courtesy of SUZUKI OF AMERICA CORP.
  7. Install retainer stoppers (2).
    NOTE: Change shape of retainer stopper depending on position of tooth on retainer (1).

    Tightening torque 

    Retainer stopper bolts a: 10 N.m (1.0 kg-m, 7.5 lb-ft) 

    Fig 6: Installing Retainer Stoppers
    G04590369Courtesy of SUZUKI OF AMERICA CORP.
  8. Check gear tooth contact.

    Apply red lead paste to tooth of drive bevel gear and turn it by hand to check its contact with drive bevel pinion. Check contact pattern, referring to following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.

    NOTE:
    • Apply red lead paste all around bevel gear but not so much as to become sticky.
    • Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.

    Gear tooth contact 

    GEAR TOOTH CONTACT DIAGNOSTIC CHART

    TOOTH CONTACT PATTERN DIAGNOSIS AND REMEDY
    G04590370
    		 NORMAL
    G04590371
    		 HIGH CONTACT 
    Pinion is positioned too far from the center of drive bevel gear.
    1. Increase thickness of pinion height adjusting shim and position pinion closer to gear center.
    2. Adjust drive bevel gear backlash to specification.
    G04590372
    		 LOW CONTACT 
    Pinion is positioned too close to the center of drive bevel gear.
    1. Decrease thickness of pinion height adjusting shim and position pinion farther from gear center.
    2. Adjust drive bevel gear backlash to specification.
    G04590373
    		 If adjustment is impossible, replace differential carrier.
    G04590374
    • Drive bevel gear or drive bevel pinion defective.
    • Poor squareness of differential carrier.
    • Differential carrier surface where gear is installed is defective.

    Replace defective part as an assembly.
    G04590375
    1. Check seating of bevel gear or differential case. (Check bevel gear for runout).
    2. If adjustment is impossible, replace drive bevel gear and pinion as a set or differential carrier.
    G04590376
    		 Replace drive bevel gear and pinion as a set or differential case, if found defective
  9. Upon completion of gear tooth contact check in Step  8, after applying sealant to breather cover (3), install breather plug (2) to differential cover (4).
  10. After applying sealant to differential cover (4), install differential cover (4) to differential carrier (1).

    "A": Sealant 99000-31110 

    Tightening torque 

    Breather cover bolt (b): 6.0 N.m (0.6 kg-m, 4.5 lb-ft) 

    Differential cover bolts: 23 N.m (2.3 kg-m, 17.0 lb-ft) 

    Fig 7: Identifying Retainer Stoppers Bolts
    G04590377Courtesy of SUZUKI OF AMERICA CORP.
  11. Caulk bevel pinion nut (2) with caulking tool (1) and hammer.
    Fig 8: Caulking Bevel Pinion Nut
    G04590378Courtesy of SUZUKI OF AMERICA CORP.
scientia non olet · About LEMON Manuals