Front Differential Assembly Disassembly and Reassembly: Disassembly

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

Fig 1: Identifying Front Differential Right Mounting 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: Removing Front Drive Shaft From Front Shaft Retainer Using Plastic Hammer
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 Rear 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 Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove snap ring (1) using snap ring pliers.
  
  Fig 5: Removing Snap Ring Using Snap Ring Pliers
  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: Driving Out Front Drive Shaft Bearing Using Special Tools
  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 Using Special Tool
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 Out Differential Side Bearing Using Special Tools
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).
  
  Fig 10: Removing Drive Bevel Gear (Hypoid Gear)
  Courtesy of SUZUKI OF AMERICA CORP.
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: Identifying Differential Grease, Pinions, Washers, Shims And Shaft
  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 Using Power Wrench (4 - 10 Magnification)
  Courtesy of SUZUKI OF AMERICA CORP.
2. Make mating marks (1) on drive bevel pinion and companion flange.
  NOTE: 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: Screwing Nut Into 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.
  NOTE: If the rear bearing is supported on the concave side of the bearing puller, the rear bearing may be damaged.
  Be sure to support the rear bearing on the flat side of the bearing puller.
  
  Fig 15: Removing Drive Bevel Pinion Rear Bearing Using Bearing Puller And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal (1) using special tool.
Special Tool

(A): 09913-50121

Fig 16: 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 17: Driving Out 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: Driving Out Rear Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.