Rear Differential Assembly Disassembly and Reassembly: Disassembly

Drive out rear drive right and left shaft using special tools.
Special Tool
1. 09942-15511
2. 09943-17912
  
  Fig 1: Identifying Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Remove rear drive right and left retainers.
Tapping rear cover flanges with plastic hammer, remove rear cover (1) and dynamic damper (if equipped).

Fig 2: Identifying Rear Cover
Courtesy of SUZUKI OF AMERICA CORP.
Disassembly rear drive right retainer as follows, if necessary.
1. Remove oil seal (1) using special tool.
  Special Tool
  1. 09913-50121
    
    Fig 3: Identifying Oil Seal & Special Tool
    Courtesy of SUZUKI OF AMERICA CORP.
2. Remove snap ring.
  
  Fig 4: Removing Snap Ring
  Courtesy of SUZUKI OF AMERICA CORP.
3. Drive out rear drive shaft bearing using special tools.
  Special Tool
  1. 09930-30104
  2. 09941-64511
    
    Fig 5: Removing Rear Drive Shaft Bearing Using Special Tools
    Courtesy of SUZUKI OF AMERICA CORP.
Disassembly rear drive left retainer in the same manner at Step 4, if necessary.
Take out differential assembly (1), outer race and shim all at once.

Fig 6: Identifying Differential Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Pull out differential side bearing (1) using special tools.
Special Tool
1. 09913-65135
2. 09925-86010
  
  Fig 7: Identifying Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Remove drive bevel gear (hypoid gear), differential gears, differential pinions and pinion shaft as follows.
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 8: Identifying Drive Bevel Gear, Aluminum Plates & Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove pinion shafts (1), differential gears, washers, differential pinions, spring washers, thrust washers and pinion joint.
  
  Fig 9: Identifying Pinion Shafts
  Courtesy of SUZUKI OF AMERICA CORP.
Remove drive bevel pinion (hypoid gear) assembly as follows.
1. Hold joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2).
  Special Tool
  1. 09922-66021
  Fig 10: Identifying Special Tool
  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 flange (2) from drive bevel pinion. Use special tool if it is hard to remove.
  Special Tool
  1. 09913-65135
  2. 09925-88210
    
    Fig 11: Identifying Special Tool
    Courtesy of SUZUKI OF AMERICA CORP.
4. Remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier.
  If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut with a plastic hammer but never directly on drive bevel pinion.
  
  Fig 12: Identifying Drive Bevel Pinion
  Courtesy of SUZUKI OF AMERICA CORP.
5. Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press.
  CAUTION: To avoid rear bearing from being damaged, support it at flat side of bearing puller.
  
  Fig 13: Identifying Drive Bevel Pinion Rear Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal (1) using special tool.
Special Tool
1. 09913-50121
Fig 14: Removing Oil Seal Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out front bearing outer race (2).

Fig 15: Removing Front Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.
Drive out rear bearing outer race (1) in the same manner as Step 11.

Fig 16: Removing Rear Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.