Rear Differential Disassembly and Reassembly: Disassembly

WARNING: This page is about a different car, the 2010 Suzuki Kizashi. However, it is still accessible from the selected car via links, so may be relevant.

Remove coupling case bolts.
Use special tool to separate coupling case (1) from differential carrier (2).
Special Tool
1. 09912-34510
Fig 1: Separating Coupling Case From Differential Carrier
Courtesy of SUZUKI OF AMERICA CORP.
Hold companion flange with special tool and then remove flange nut.
Special Tool
1. 09930-40113
Fig 2: Holding Companion Flange With Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove companion flange (1) from pinion.
NOTE: Use special tool if it is hard to remove.

Special Tool
1. 09913-65135
Fig 3: Removing Companion Flange From Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Use hydraulic press to remove coupling assembly (1).
CAUTION: Do not drop coupling assembly. Replace it with a new one if it is dropped.

Fig 4: Pressing Coupling Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Use special tool to remove oil seal.
Special Tool
1. 09913-50121
Fig 5: Removing Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Use snap ring pliers to remove snap ring (1).

Fig 6: Identifying Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Use special tool and hydraulic press to remove bearing.
Special Tool
1. 09913-75830
Fig 7: Removing Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Use special tool to remove oil seals from rear differential (1).
NOTE: It is also possible to remove oil seats after removing differential cover.

Special Tool
1. 09913-50121
Fig 8: Removing Oil Seals From Rear Differential
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential cover bolts.
Use special tool to remove differential cover (1).
Special Tool
1. 09912-34510
Fig 9: Removing Differential Cover
Courtesy of SUZUKI OF AMERICA CORP.
Remove differential cover plate from differential carrier.
Remove the following parts together from differential carrier (3):
- Differential case
- Differential side right bearing (2)
- Differential side left bearing (1)
- Differential side shim (4)
  
  Fig 10: Identifying Differential Side Right Bearing And Side Left Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Use special tools to pull out differential side bearings (1).
Special Tool
1. 09913-60910
2. 09925-88210
Fig 11: Pulling Out Differential Side Bearings
Courtesy of SUZUKI OF AMERICA CORP.
First use vise, with aluminum plates (2) placed on it, to grip differential case.
Remove bevel gear (hypoid gear) (3).

Fig 12: Identifying Bevel Gear (Hypoid Gear)
Courtesy of SUZUKI OF AMERICA CORP.
Remove pinion shaft pin with special tool and hammer.
Special Tool
1. 09922-85811
Disassemble differential gears (2), pinions (3), washers and shaft (4) in differential case (1).

Fig 13: Identifying Differential Gears, Pinions, Washers, Shaft And Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove bevel pinion nut (1) with special tool.
Special Tool
1. 09927-27910
Fig 14: Removing Bevel Pinion Nut
Courtesy of SUZUKI OF AMERICA CORP.
Remove the following parts from differential carrier (4):
- Bevel pinion (1)
- Spacer (2)
- Front bearing (3)
  
  Fig 15: Identifying Bevel Pinion, Spacer And Front Bearing
  Courtesy of SUZUKI OF AMERICA CORP.
Use bearing puller (3) and hydraulic press to remove rear bearing (2) from bevel pinion (1).

Fig 16: Removing Rear Bearing From Bevel Pinion
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal from differential carrier.
Use hammer and brass bar (1) to remove bearing outer race (front (3) and rear (2)).

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