Front Differential Assembly Disassembly and Reassembly: Disassembly

Remove front differential right mounting (1) and rear mounting (2).

Fig 1: Identifying Front Differential Right And Rear Mounting
Courtesy of SUZUKI OF AMERICA CORP.
Drive out front drive shaft (1) from front shaft retainer (2) using plastic hammer (3).

Fig 2: Tapping Front Drive Shaft From Front Shaft Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential side right retainer and front drive shaft retainer, and then remove rear cover (1).

Fig 3: Identifying Differential Cover
Courtesy of SUZUKI OF AMERICA CORP.
Disassembly front drive shaft retainer as follows, if necessary.
1. Remove oil seal (1) from front drive shaft retainer using special tool.
  Special Tool
  
  (A): 09913-50121
  
  Fig 4: Removing Oil Seal From Front Drive Shaft Retainer
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove snap ring (1) using snap ring plier.
  
  Fig 5: Removing Snap Ring
  Courtesy of SUZUKI OF AMERICA CORP.
3. Drive out front drive shaft bearing using special tools.
  Special Tool
  
  (A): 09930-30104
  
  (B): 09941-64511
  
  Fig 6: Removing Front Drive Shaft Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Support differential side right retainer (1) with soft jawed vise and remove oil seal (2) from differential side right retainer using special tool, if necessary.
Special Tool

(A): 09913-50121

Fig 7: Removing Oil Seal From Differential Side Right Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Take out differential assembly (1), outer race and shim all at once.

Fig 8: Identifying Differential Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Pull out differential side bearing (1) using special tools.
Special Tool

(A): 09913-65135

(B): 09925-86010

Fig 9: Pulling Differential Side Bearing
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 (4) placed on vise first, grip differential case (3) with it and remove drive bevel gear (hypoid gear) (2) by removing its bolts (1).
2. Drive out spring pin (1) with special tool and hammer.
  Special Tool
  
  (A): 09922-85811
3. Disassemble differential grease (5), pinions (3), washers (4), shims (6) and shaft (2) in differential case (7).
  
  Fig 11: Disassembling View Of Differential Grease
  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 and bevel pinion washer by using power wrench (4 - 10 magnification) (2).
  Special Tool
  
  (A): 09922-66021
  
  Fig 12: Removing Flange Nut And Bevel Pinion Washer
  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
  
  (A): 09913-65135
  
  (B): 09925-88210
  
  Fig 13: Removing Flange From Drive Bevel Pinion
  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 14: Tapping 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 15: Removing Drive Bevel Pinion Rear Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal (1) using special tool.
Special Tool

(A): 09913-50121

Fig 16: Removing Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out front bearing outer race (2).

Fig 17: Tapping 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 18: Tapping Rear Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.