Rear Differential Disassembly and Reassembly: Disassembly

Remove rear mounting bracket from rear differential, referring to FRONT MOUNTING ARM AND/OR REAR MOUNTING BRACKET ASSEMBLY REMOVAL AND INSTALLATION .
Remove drive shaft flanges.
Separate coupling case from differential carrier using special tool.
Special Tool

09912-34510
Hold companion flange with special tool and then remove flange nut.
Special Tool

(A): 09930-40113

Fig 1: Holding Companion Flange With Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove companion flange (1) from pinion. Use special tool if it is hard to remove.
Special Tool

(A): 09913-65135

Fig 2: Removing Companion Flange From Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Remove coupling assembly (1) by using hydraulic press.
CAUTION: Do not drop coupling assembly. If it is dropped, replace it with a new one.

Fig 3: Pressing Coupling Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Disassemble coupling case as follows, if necessary.
1. Remove oil seal using special tool.
  Special Tool
  
  (A): 09913-50121
  
  Fig 4: Identifying Special Tool On Oil Seal
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove snap ring using snap ring pliers.
3. Remove bearing using special tool and hydraulic press.
  Special Tool
  
  (A): 09913-75830
  
  Fig 5: Identifying Special Tool On Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seals from rear differential (1) using special tool.
Special Tool

(A): 09913-50121

Fig 6: Identifying Special Tool On Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential cover (1) using special tool, and then take out differential assembly, outer race and shim all at once.
Special Tool

(A): 09912-34510

Fig 7: Identifying Differential Cover
Courtesy of SUZUKI OF AMERICA CORP.
Pull out differential side bearings (1) using special tools.
Special Tool
1. 09913-60910
2. 09925-88210
  
  Fig 8: Pulling Out Differential Side Bearings
  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 9: Identifying Drive Bevel Gear & Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
2. Drive out differential side pinion shaft pin with special tool and hammer.
  Special Tool
  
  (B): 09922-85811
3. Disassemble differential gears (2), pinions (3), washers and shaft (4) in differential case (1).
  
  Fig 10: Identifying Differential Gears, Pinions, Washers & Shaft In Differential Case
  Courtesy of SUZUKI OF AMERICA CORP.
Remove bevel pinion nut with special tool.
Special Tool

(A): 09927-27910

Fig 11: Holding Bevel Pinion Nut
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear bearing (2) from drive bevel pinion (1) by using bearing puller (3) and hydraulic press.

Fig 12: Removing Rear Bearing From Drive Bevel Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out front bearing outer race (2).

Fig 13: Identifying Brass Bar & Front Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out rear bearing outer race (2).

Fig 14: Identifying Brass Bar & Rear Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.