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Rear Differential Disassembly and Assembly: Disassembly

  1. Remove differential cover (1).
  2. Remove breather plug (2) from differential cover (1).
    Fig 1: Removing Breather Plug From Differential Cover
    G04590347Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove differential side bearing stopper and then remove differential side bearing retainer.

    Special Tool 

    (A): 09923-58520 

    Fig 2: Removing Differential Side Bearing Retainer
    G04590348Courtesy of SUZUKI OF AMERICA CORP.
  4. Using some appropriate rod (1), drive out differential side bearing outer races (2).
    NOTE: When driving out differential side bearing outer races, be very careful not to cause damage to tooth surface of bevel gear.
  5. Remove bevel gear assembly (3).
    Fig 3: Removing Bevel Gear Assembly
    G04590349Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove bevel gear bolts (1) and then remove drive bevel gear (2).
  7. Remove differential side bearings (3).
    Fig 4: Removing Differential Side Bearings
    G04590350Courtesy of SUZUKI OF AMERICA CORP.
  8. Drive out differential side pinion shaft pin with special tool and hammer.

    Special Tool 

    1. (B): 09922-85811 
    2. Disassemble differential side gears (2), pinions (3), washers and shaft (4) in differential case (1).
      Fig 5: Disassembling Differential Side Gears
      G04590351Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove caulking of bevel pinion nut with special tool and power wrench (1).

    Special Tool 

    1. (C): 09930-40113 
      Fig 6: Removing Caulking Of Bevel Pinion Nut
      G04590352Courtesy of SUZUKI OF AMERICA CORP.
  10. Remove companion flange (1) and washer from drive bevel pinion, and then drive out drive bevel pinion.

    Special Tool 

    1. D 09913-85230 
    2. E 09913-65135 
      Fig 7: Removing Companion Flange And Washer From Drive Bevel Pinion
      G04590353Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove rear bearing (2) from drive bevel pinion (1) by using bearing puller (3) and press.
    Fig 8: Removing Rear Bearing From Drive Bevel Pinion
    G04590354Courtesy of SUZUKI OF AMERICA CORP.
  12. Using a hammer and brass bar (1), drive out front bearing outer race (2).
    Fig 9: Removing Front Bearing Outer Race
    G04590355Courtesy of SUZUKI OF AMERICA CORP.
  13. Using a hammer and brass bar (1), drive out rear bearing outer race (2).
    Fig 10: Removing Rear Bearing Outer Race
    G04590356Courtesy of SUZUKI OF AMERICA CORP.