Rear Differential Disassembly and Reassembly: Disassembly

WARNING: This page is about a different car, the 2011 Suzuki SX4. However, it is still accessible from the selected car via links, so may be relevant.

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: Removing Flange Nut Using 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 Using Special Tool
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: Removing Coupling Assembly By Using Hydraulic Press
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: Removing Oil Seal Using Special Tool
  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: Removing Bearing Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seals from rear differential (1) using special tool.
Special Tool

(A): 09913-50121

Fig 6: Removing Oil Seals From Rear Differential Using Special Tool
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: Removing Differential Cover Using Special Tool
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 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. 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 And Shaft In Differential Case
  Courtesy of SUZUKI OF AMERICA CORP.
Remove bevel pinion nut with special tool.
Special Tool

(A): 09927-27910

Fig 11: Removing Bevel Pinion Nut With Special Tool
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 (1) By Using Bearing Puller
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out front bearing outer race (2).

Fig 13: Driving Out Front Bearing Outer Race Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out rear bearing outer race (2).

Fig 14: Driving Out Rear Bearing Outer Race Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.