Rear Differential
UNIT REPAIR
DISASSEMBLY
1. Hold differential assembly securely and put identification marks on differential side bearing caps.
2. Take off differential side bearing lock plates and differential side bearing caps by removing their bolts and then take out bearing adjusters, side bearing outer races and drive bevel gear with differential case.
3. Remove drive bevel gear, pinion gear and pinion shaft.
[A/T model]
1. With aluminum plates placed on vise first, grip differential case with it and remove bevel gear by removing its bolts.
2. Remove differential left case from differential right case.
3. Drive out spring pin with special tool (A) and hammer and disassemble differential side gears, pinions, washers and shaft in differential case.
Special Tool
(A): 09922-85811
[M/T model]
1. Remove bevel gear by removing its bolts in the same manner as step 1 of A/T model.
2. There are 8 bolts fastening two differential case halves together. Remove these bolts to sever right-hand case half from left-hand one, and take off right-hand one.
Special Tool
(B): 09930-40113
3. Remove pinion shaft, side gears, washers, differential pinions, spring washers, thrust washers.
4. Remove side bearings Using special tools (C) & (D), pull out differential side bearings.
Special Tool
(C): 09913-85230
(D): 09913-61510
5. Remove bevel pinion assembly.
1. Hold universal joint flange with special tool (E) and then remove flange nut by using power wrench.
Special Tool
(E): 09922-66020
2. Make mating marks on drive bevel pinion and companion flange.
CAUTION: Don't make mating mark on the coupling surface of the flange.
3. Remove companion flange from pinion. Use special tool if it is hard to remove.
Special Tool
(F): 09913-65135
4. Remove bevel pinion with rear bearing, shim and spacer from carrier. If it is hard to remove, screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on pinion.
5. Remove bevel pinion rear bearing by using bearing puller and press.
6. Using a hammer and brass bar, drive out front bearing outer race with bearing and oil seal.
7. Drive out rear bearing outer race in the same way as in step 6).
INSPECTION
- Check companion flange for wear or damage.
- Check bearings for wear or discoloration.
- Check differential carrier for cracks.
- Check drive bevel pinion and bevel gear for wear or cracks.
- Check side gears, pinion gears and pinion shaft for wear or damage.
- Check side gear spline for wear or damage.
ADJUSTMENT AND REASSEMBLY
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 below.
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.
DIFFERENTIAL CARRIER
For press-fitting bevel pinion bearing outer races, use special tools (A), (B) & (C) as shown.
Special Tool
(A): 09924-74510
(B): 09926-68310
(C): 09913-75510
DIFFERENTIAL CASE
[A/T model]
1. After applying differential oil to side gear, pinions, pinion shaft, thrust washer and spring washer, install them in differential right case. For correct installing direction of thrust washer and spring washer, refer to figure.
2. Check pinion gear for smooth rotation.
3. Align pinion shaft hole position with differential case and drive in 3 spring pins till they are flush with end surface of case.
Special Tool
(A): 09922-85811
4. In the same manner as described in Step 1), install thrust washer, spring washer and side gear.
5. Put bevel gear on differential case and fasten them with bolts by tightening them to specified torque.
Use thread lock cement for bolts.
CAUTION: Use of any other bolts than that specified is prohibited.
"A": Cement 99000-32020
Tightening Torque
(a): 85 Nm (8.5 kg-m, 61.5 ft. lbs.)
6. Install special tool (B) to differential case assembly and check that preload is within specification below. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special Tool
(B): 09928-06010-002
Side gear preload: Max. 2.5 Nm (0.25 kg-m, 1.8 ft. lbs.)
[M/T model]
1. After applying differential oil to side gear, pinions, pinion shafts, washer, thrust washer and spring washer, install them in differential left case. For correct installing direction of thrust washer and spring washer, refer to figure.
2. When installing pinion shaft No.2 (shorter) into differential case and pinion, insert its "a" side into pinion joint.
NOTE: "a" is longer than "b". ("a" > "b")
3. Check pinion gear for smooth rotation.
4. In the same manner as described in Step 1), install thrust washer, spring washer and side gear.
5. Install differential right case and then tighten bolts to specified torque.
"A": Cement 99000-32020
Tightening Torque
(a): 41 Nm (4.1 kg-m, 30.0 ft. lbs.)
6. Install bevel gear in the same manner as step 5 of A/T model.
7. Check preload in the same manner as step 6 of A/T model.
DIFFERENTIAL SIDE BEARING
1. Press-fit side bearing with special tool and press.
Special Tool
(A): 09944-66020
2. Hold bearing press-fitted in Step 1) with holder and press-fit side bearing on the other side.
NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.
Special Tool
(A): 09944-66020
(B): 09951-16060
DRIVE BEVEL PINION
To engage bevel pinion and gear correctly, it is pre-required to install bevel pinion to differential carrier properly by using adjusting shim(s). Shown are the relative positions of bevel pinion, differential carrier and mounting dummy.
1. Install special tools with bearings and universal joint flange to differential carrier.
NOTE:
^ This installation requires universal joint flange not equipped with groove on flange periphery.
^ This installation requires no spacer or oil seal.
Special Tool
(B): 09926-78311
(F): 09951-46010 (M/T model only)
2. Tighten flange nut so that specified bearing preload is obtained.
NOTE: Before taking measurement with spring balance or torque wrench, check for rotation by hand and apply small amount of oil to bearings.
Special Tool
(B): 09926-78311
(C): 09922-75222
Pinion bearing preload: 9.0 - 17.0 kg-cm (7.8 - 14.7 inch lbs.)
Spring measure reading with special tool: 1.8 - 3.4 kg (4.0 - 7.5 lbs.)
3. 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).
Special Tool
(A): 09900-20606
(B): 09926-78311
4. Place zero-adjusted mounting dummy and dial gauge set on pinion dummy 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.
^ Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.
Special Tool
(A): 09900-20606
(B): 09926-78311
(D): 09951-16070
(E): 09922-77250 (M/T model only)
5. Obtain adjusting shim thickness by using measured value by dial gauge (which represents "c") in following equation.
97 (A/T model) or 102 (M/T model) in above equation is "a" + "b" of mounting dummy (special tool (B)) as shown.
6. Select adjusting shim(s) closest to calculated value from among following available sizes and put it in place and then press-fit rear bearing.
"g": Closest value to "f" (Calculated)
Special Tool
(G): 09925-18010
(H): 09927-66010
7. With new pinion spacer inserted as shown, install front bearing to differential carrier.
NOTE:
^ Make sure to use new spacer for reinstallation.
^ Apply oil to bearings.
8. Using special tool and plastic hammer, drive oil seal into differential carrier till it becomes flush with carrier end. Then apply grease to oil seal lip.
"A": Grease 99000-25010
Special Tool
(i): 09951-18210
9. While tightening flange nut gradually with special tool (J) and power wrench, set preload of pinion to specification.
NOTE:
^ Before taking measurement with spring balance or torque wrench, check for smooth rotation by hand.
^ Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange.
^ Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.
Pinion bearing preload: 0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 inch lbs.)
Spring measure reading with special tool: 18 - 34 N (1.8 - 3.4 kg, 4.0 - 7.5 lbs.)
Special Tool
(C): 09922-75222
(J): 09922-66020
ASSEMBLING UNIT
1. Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2. Install case assembly in carrier.
3. Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.
4. Align match marks on cap and carrier. Screw in two side bearing cap bolts two or three turns and press down bearing cap by hand.
NOTE: If bearing cap does not fit tightly on carrier, side bearing adjuster is not threaded properly. Reinstall adjuster.
Tighten cap bolts.
Provisional Tightening Torque
(a): 15 Nm (1.5 kg-m, 11.0 ft. lbs.)
5. Tighten both bearing adjusters so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.
NOTE:
^ Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
^ As a practical measure following would be recommended to obtain specified backlash and side bearing preload at the same time.
1. Obtain specified backlash by turning both adjusters inward lightly.
2. Tighten both adjusters further by one notch at a time.
^ Measure at least 4 points on drive bevel gear periphery.
Standard backlash 0.13 - 0.18 mm (0.005 - 0.007 inch)
Special Tool
(A): 09930-40120
(B): 09930-40113
(C): 09900-20701
6. Measure preload of pinion with spring balance or torque wrench and check composite preload of pinion bearing and side bearing.
NOTE: Standard preload is shown in graph, which should be read as follows.
Example:
When preload of bevel pinion is 26 N (2.6 kg, 5.73 lbs.), acceptable composite preload of both pinion bearings and side bearings should be between 2.8 and 3.2 kg/6.17 and 7.05 lbs.
Special Tool
(B): 09922-75222
- Bearing preload can be checked roughly by using flange holder as shown in figure. In this measurement, holder arm itself will work as balance weight and torque will be replaced with angle. However, flange should be rotated very slowly with hand support so as not to allow over revolution due to inertia.
- Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specification, if failed to obtain specified measurements first.
Special Tool
(E): 09922-66020
7. Torque bearing cap bolts to specification and install bearing lock plates.
Tightening Torque
(b): 12 Nm (1.2 kg-m, 9.0 ft. lbs.)
(c): 85 Nm (8.5 kg-m, 61.5 ft. lbs.)
8. As final step, check gear tooth contact as follows.
1. After cleaning 10 bevel gear teeth, paint them with gear marking compound evenly by using brush or sponge etc.
2. Turn gear to bring its painted part in mesh with bevel pinion and turn it back and forth by hand to repeat their contact.
3. Bring painted part up and check contact pattern, referring to the chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.
NOTE: Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
9. Upon completion of gear tooth contact check in Step 8, caulk flange nut with caulking tool and hammer.
REMOUNTING
1. Clean mating surfaces of rear axle and differential assembly and apply sealant (Suzuki bond 1215) to axle side evenly.
"A": Sealant 99000-31110
2. Install differential assembly to axle and fix it with nuts tightened to specified torque.
Tightening Torque
(a): 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
3. Install propeller shaft to joint flange aligning match marks and torque flange bolts to specification.
Tightening Torque
(c): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)
4. Install right and left rear axle shafts and drums.
5. Install wheels.
6. Fill hypoid gear oil as specified and tighten plug to specification. Lower lift.