Rear Differential Assembly Disassembly and Reassembly: Disassembly

Drive out rear drive shaft using special tools.
Special Tool

(A): 09942-15511

(B): 09943-17912

Fig 1: Removing Rear Drive Shaft Using Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
Remove rear drive right and left retainers.
Tapping rear cover flanges with plastic hammer, remove rear cover (1) and dynamic damper (if equipped).

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

(A): 09913-50121

Fig 6: Removing Oil Seal From Differential Side Left Retainer Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Take out differential assembly (1), outer race and shim all at once.

Fig 7: 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 8: 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 (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: Removing Drive Bevel Gear (Hypoid Gear)
  Courtesy of SUZUKI OF AMERICA CORP.
2. Remove pinion shafts (1), differential gears, washers, differential pinions, spring washers, thrust washers and pinion joint.
  
  Fig 10: Identifying Pinion Shafts
  Courtesy of SUZUKI OF AMERICA CORP.
Remove drive bevel pinion (hypoid gear) assembly as follows.
1. Hold joint flange (1) with special tool and then remove flange nut and bevel pinion washer.
  Special Tool
  
  (A): 09930-40113
  
  Fig 11: 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.
  NOTE: Do not make mating mark on the coupling surface of the flange.
3. Remove flange (2) and flange shim from drive bevel pinion. Use special tool if it is hard to remove.
  Special Tool
  
  (A): 09913-65135
  
  (B): 09925-88210
  
  Fig 12: Removing Flange And Flange Shim 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 13: Removing Drive Bevel Pinion With Rear Bearing, Shim And Spacer From Carrier
  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 14: 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 15: 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 16: Removing Front Bearing Outer Race Using Hammer And Brass Bar
Courtesy of SUZUKI OF AMERICA CORP.
Drive out rear bearing outer race (1) in the same manner as Step 11).

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