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Home >> Suzuki >> 2008 >> XL7 Base, AWD >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Repair Instructions >> Differential Replacement >> Installation Procedure
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Installation Procedure

Fig 1: Identifying Rear Differential Assembly In Rear Cradle
G05469429Courtesy of SUZUKI OF AMERICA CORP.
NOTE: When positioning the rear differential assembly in the rear cradle, leave enough room to access the clutch control module.
  1. If replacing the clutch control module, the new module must be programmed. Refer to CONTROL MODULE REFERENCES .
  2. Position the rear differential assembly in the rear cradle.
    Fig 2: Identifying Small Electrical Connector And Large Electrical Connector
    G05469430Courtesy of SUZUKI OF AMERICA CORP.
  3. Install the small electrical connector (1).
  4. Install the large electrical connector (2).
    NOTE: When installing the front mounting bolts tighten by hand.
  5. Install the front mounting nuts (3).
    Fig 3: Identifying Rear Differential Support Bushing Bolts
    G05469431Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the rear differential support bushing bolts.
  7. Raise the rear differential assembly into place.
    CAUTION: Refer to FASTENER NOTICE .
  8. Tighten the front mounting nuts.

    Tightening torque 

    Tighten the front mounting nuts to 122 N.m (90 lb ft). 

  9. Tighten the rear differential support bushing bolts.

    Tightening torque 

    Tighten the nuts to 188 N.m (139 lb ft). 

  10. Remove the transmission jack stand.
  11. Install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
  12. Install the rear wheel drive shafts. Refer to REAR WHEEL DRIVE SHAFT REPLACEMENT .
  13. Install the rear wheel drive module clutch housing. Refer to REAR WHEEL DRIVE MODULE CLUTCH HOUSING REPLACEMENT .
  14. Install the muffler assembly. Refer to MUFFLER REPLACEMENT .
  15. Install the spare tire.
  16. Fill the rear differential assembly with fluid, if drained. Refer to REAR AXLE LUBRICANT REPLACEMENT .
  17. Lower the vehicle.