Rear Differential Disassembly and Reassembly: Reassembly

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.

Reference: REAR DIFFERENTIAL INSPECTION

Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described in the following.

CAUTION:

Bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
When replacing taper roller bearing, replace as inner race & outer race assembly.

Press-fit bevel pinion bearing outer races to differential carrier (1) by using special tools and hydraulic press as shown in the figure.
Special Tool
1. 09913-85210
2. 09913-75510
  
  Fig 1: Fitting Bevel Pinion Bearing Outer Races To Differential Carrier Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
After applying differential oil to differential gears (4), pinions (5), pinion shaft (3), side washers (1), spring washers (7) and pinion washers (2), install them in differential case (6).
For correct installing direction of side washers and spring washers, refer to figure.

NOTE: Used left and right differential side washers are not interchangeable.

Fig 2: Identifying Differential Gears, Pinions, Pinion Shaft, Side Washers, Spring Washers And Pinion Washers
Courtesy of SUZUKI OF AMERICA CORP.
Check pinion gear (1) for smooth rotation.

Fig 3: Checking Pinion Gear For Smooth Rotation
Courtesy of SUZUKI OF AMERICA CORP.
Align holes of pinion shaft and differential case and drive in differential pinion shaft pin till they are flush with end surface of case.
Special Tool

(A): 09922-85811

Fig 4: Aligning Holes Of Pinion Shaft And Differential Case And Drive In Differential Pinion Shaft Pin
Courtesy of SUZUKI OF AMERICA CORP.
Put bevel gear (2) on differential case (3) and tighten new bolts (1) to specified torque.
CAUTION: Use of any other bolts than that specified is prohibited.

Tightening torque

Bevel gear bolt (a): 78 N.m (7.8 kg-m, 56.5 lbf-ft)

Fig 5: Putting Bevel Gear On Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit differential right side bearing (1) with special tools and hydraulic press.
Special Tool
1. 09913-80113
2. 09926-48010
  
  Fig 6: Fitting Differential Right Side Bearing With Special Tools
  Courtesy of SUZUKI OF AMERICA CORP.
Hold differential right side bearing (2) with special tool and press-fit differential left side bearing (1) with special tools and hydraulic press.
NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.

Special Tool
1. 09913-80113
2. 09926-48010
3. 09925-88210
  
  Fig 7: Fitting Differential Left Side Bearing With Special Tools
  Courtesy of SUZUKI OF AMERICA CORP.
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy.
Special Tool
1. 09922-76120
2. 09922-76250
3. 09922-76140
4. 09922-76420
5. 09922-76330
6. 09922-76150
7. 09922-76340
8. 09922-76530
  
  Fig 8: Installing Drive Bevel Pinion To Differential Carrier
  Courtesy of SUZUKI OF AMERICA CORP.
Set special tools and make drive bevel pinion mounting dummy.
Special Tool
1. 09922-76120
2. 09922-76250
Install dial gauge (1) to mounting dummy as shown in figure.
Special tool set distance

"a": 38.0 mm (1.496 in.)

"b": 0 mm (0.000 in.)

Fig 9: Installing Dial Gauge To Mounting Dummy
Courtesy of SUZUKI OF AMERICA CORP.
Set special tools and make drive bevel pinion dummy.
Special Tool
1. 09922-76140
2. 09922-76420
3. 09922-76330
4. 09922-76340
  
  Fig 10: Identifying Special Tools For Drive Bevel Pinion Dummy
  Courtesy of SUZUKI OF AMERICA CORP.
Apply gear oil to drive bevel pinion bearings, install special tools with bearings to differential carrier as shown in figure.
Special Tool
1. 09922-76140
2. 09922-76420
3. 09922-76330
4. 09922-76340
5. 09922-76150
6. 09922-76530
  NOTE: This installation requires no spacer or oil seal.
  
  Fig 11: Installing Special Tools With Bearings To Differential Carrier
  Courtesy of SUZUKI OF AMERICA CORP.
Tighten bevel pinion nut (special tool) (1) so that specified bearing preload is obtained.
NOTE: Before taking measurement, check for rotation by hand more than 15 revolutions.

Pinion bearing preload (at 50 RPM)

: 1.3 - 2.6 N.m (13.0 - 26.0 kgf-cm, 11.3 - 22.6 lb-in.)

Fig 12: Tightening Bevel Pinion Nut (Special Tool)
Courtesy of SUZUKI OF AMERICA CORP.
Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate.
NOTE:
- When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge.
- With dial gauge set, turn dummy back and forth by hand a couple of times and attain accurate 0 (zero) adjustment.
- It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).
  
  Fig 13: Identifying Dial Gauge On Bevel Pinion Mounting Dummy
  Courtesy of SUZUKI OF AMERICA CORP.
Place zero-adjusted mounting dummy (1) and dial gauge set on pinion dummy (2) and take measurement between zero position and extended dial gauge measuring tip.
NOTE:
- Repeat turning back and forth of dummy and measure distance as far as top surface of pinion dummy accurately.
- When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
  
  Fig 14: Identifying Mounting Dummy And Dial Gauge Set
  Courtesy of SUZUKI OF AMERICA CORP.
Necessary adjusting shim thickness is the same value as measured value by dial gauge.
Necessary shim thickness "e" = Dial gauge measured value "c"
Select adjusting shim(s) (2) closest to obtained value from among the following available sizes and put it in place and then press-fit rear bearing (1) to bevel pinion (3).
Available shim thickness

0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81, 0.84 and 0.87 mm (0.012, 0.023, 0.024, 0.026, 0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034 in.)

Special Tool

(D): 09925-18011

Fig 15: Fitting Rear Bearing To Bevel Pinion
Courtesy of SUZUKI OF AMERICA CORP.
With new pinion spacer (2) inserted as shown in figure, install front bearing (1) to differential carrier (3).
NOTE: Apply differential oil to front and rear bearings.

Fig 16: Installing Front Bearing To Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) as shown in figure. Then apply grease to oil seal lip.
NOTE: Install oil seal horizontally to surface of differential carrier.

"A": Grease 99000-25011 (SUZUKI Super Grease A)

Distance between differential carrier and oil seal "a"

: 0.5 - 1.5 mm (0.02 - 0.06 in.)

Special Tool

(A): 09913-85210

Fig 17: Checking Distance Between Differential Carrier And Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Tighten bevel pinion nut (1) gradually with special tool to specified torque while turning bevel pinion. Set bearing preload of bevel pinion to specification.
NOTE:
- Before taking measurement with torque wrench, check for smooth rotation with turning bevel pinion 15 revolutions or more by hand.
- Be sure to tighten gradually and carefully till specified pinion bearing preload is obtained. Turning back overtightened flange nuts should be avoided.
- Measure pinion bearing preload while turning bevel pinion about 50 RPM.
- Write down measured value of bevel pinion bearing preload for differential side bearing shim adjustment.
Special Tool

(A): 09927-27910

Tightening torque

Bevel pinion nut: 230 - 340 N.m (23.0 - 34.0 kg-m, 166.5 - 246.0 lbf-ft)

Bevel pinion bearing preload (Bevel pinion rotational torque)

: 1.3 - 2.6 N.m (13.0 - 26.0 kgf-cm, 11.3 - 22.6 lb-in.)

Fig 18: Checking Bevel Pinion Bearing Preload
Courtesy of SUZUKI OF AMERICA CORP.
Install differential case assembly, bearing outer races, removed shim and differential cover, temporarily.
NOTE:
- Used left and right outer races are not interchangeable.
- When measuring bevel pinion bearing preload, install differential cover with sealant not applied.
Select differential side bearing shim so that bevel pinion bearing preload may be specified value.
NOTE: Select shims so that thickness of right side shims and left side shims become almost even.

Bevel pinion bearing preload

Preload measured in Step 20 ) + 0.3 - 0.7 N.m (3 - 7 kgf-cm, 2.6 - 6.0 lb-in.)

Available shim thickness

0.45, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65 and 2.70 mm (0.017, 0.090, 0.092, 0.094, 0.096, 0.098, 0.100, 0.102, 0.104 and 0.106 in.)

Fig 19: Checking Shim Thickness
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential cover.
To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear.
If bevel gear backlash is out of specification, repeat Step 22).
NOTE:
- Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
- Measure at least 4 points on drive bevel gear periphery.
Drive bevel gear back lash

0.1 - 0.2 mm (0.004 - 0.008 in.)

Special Tool
1. 09900-20607
2. 09900-20701
  
  Fig 20: Checking Drive Bevel Gear Back Lash
  Courtesy of SUZUKI OF AMERICA CORP.

As final step, check gear tooth contact as follows.

After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact.
Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table.
NOTE: Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.

Fig 21: Checking Gear Tooth Contact
Courtesy of SUZUKI OF AMERICA CORP.

GEAR TOOTH CONTACT REFERENCE CHART

Tooth Contact Pattern	Diagnosis and Remedy
	Normal
	High Contact Pinion is positioned too far from the center of drive bevel gear (1). Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. Adjust drive bevel gear backlash to specification.
	Low Contact Pinion is positioned too close to the center of drive bevel gear (1). Decrease thickness of pinion (2) height adjusting shim and position pinion farther from gear center. Adjust drive bevel gear backlash to specification.
	If adjustment is impossible, replace differential carrier.
	Check seating of bevel gear or differential case. (Check bevel gear for runout.) If adjustment is impossible, replace drive bevel gear and pinion set or differential carrier.
	Replace drive bevel gear and pinion set or differential case.

Clean mating surface of differential carrier (1) and differential cover, apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate differential cover with differential carrier, and then tighten bolts to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)

Tightening torque

Differential cover bolt: 23 N.m (2.3 kg-m, 17.0 lbf-ft)

Fig 22: Identifying Differential Cover And Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Assemble coupling case as follows.
1. Install bearing using special tool and hydraulic press.
  Special Tool
  
  (A): 09913-75830
  
  Fig 23: Installing Bearing Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
2. Install snap ring using snap ring pliers.
3. Apply grease to oil seal lip, install oil seal (2) to coupling case (1) using special tool as shown in figure.
  NOTE: Install oil seal horizontally to surface of coupling case.
  
  "A": Grease 99000-25011 (SUZUKI Super Grease A)
  
  Distance between case and oil seal "a"
  
  : 1.5 - 2.5 mm (0.06 - 0.10 in.)
  
  Special Tool
  
  (A): 09913-75810
  
  Fig 24: Checking Distance Between Case And Oil Seal
  Courtesy of SUZUKI OF AMERICA CORP.
Install spacer (1) to coupling assembly (2) as shown in figure.

Fig 25: Installing Spacer To Coupling Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install grommet of coupling harness into groove of coupling case and then install coupling assembly by using hydraulic press.
Install companion flange to pinion, and then hold companion flange with special tool and tighten flange nut.
Tightening torque

Flange nut: 110 N.m (11.0 kg-m, 79.5 lbf-ft)

Special Tool

(A): 09930-40113

Fig 26: Tightening Flange Nut
Courtesy of SUZUKI OF AMERICA CORP.
Clean mating surface of differential carrier (1) and coupling case (2), apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate coupling case with differential carrier as shown in figure, and then tighten bolts to specified torque.
"A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)

Tightening torque

Coupling case bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)

NOTE: Install coupling pin (3) by fitting it to groove (4) of coupling case.

Fig 27: Installing Coupling Pin
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to oil seal lip, and then install oil seals (1) to rear differential (2) using special tool as shown in figure.
NOTE: Install oil seal horizontally to surface of rear differential case.

"A": Grease 99000-25011 (SUZUKI Super Grease A)

Distance between rear differential and oil seal "a"

: 1.0 - 2.0 mm (0.04 - 0.08 in.)

Special Tool

(A): 09913-75810

Fig 28: Checking Distance Between Rear Differential And Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Install drive shaft flange.
Install rear mounting bracket to rear differential referring to FRONT MOUNTING ARM AND/OR REAR MOUNTING BRACKET ASSEMBLY REMOVAL AND INSTALLATION .