Differential Mount: Service and Repair

Rear Differential Mounting Removal and Installation

NOTE:

Special tool (09914-95410) consists of bolt set (1), installer (2), attachment (3) and remover (4).






Removal

1) Lift up vehicle and drain oil from rear differential.
2) Remove rear differential from vehicle. Rear Differential Dismounting and Remounting
3) Remove rear differential front mounting bracket (1) from rear differential (2).





4) Using attachment (3) in special tool and hydraulic press, remove rear differential front mounting (2) from rear differential front mounting bracket (1).

NOTE:
Either mounting of type [A] or type [B] is installed. The type is distinguish by the shape. Distinguish between types [A] and [B] by the shape in order to install the same type of mounting.

Special Tool
09914-95410









5) Using special tool, remove rear differential rear mounting (1) from rear suspension frame (2) as follows.
Special Tool
09914-95410

a) Apply a coating of molybdenum disulfide grease to bolt thread and washers of bolt set (3) in special tool, indicated by "A".

"A" Grease: 99000-25280 (SUZUKI Molybdenum Grease L)

b) Set remover (5), attachment (4) and bolt set (3) in special tool to rear differential rear mounting (1) as shown in figure.
c) While holding bolt (3), tighten nut and remove rear differential rear mounting from rear suspension frame (2).











Installation

1) Clean mounting holes in rear suspension frame where rear differential rear mountings come in contact with.
2) Install new rear differential rear mounting (1) of the same type as the removed mounting to rear suspension frame (2) as follows.
a) Apply a coating of molybdenum disulfide grease to threaded portion and washer of bolt set (3).

"A" Grease: 99000-25280 (SUZUKI Molybdenum Grease L)

b) Put new rear differential rear mounting to rear suspension frame so that their slits and arrow mark are located as shown in figure.











c) Set attachment (5), installer (4) and bolt set (3) in special tool to rear differential rear mounting (1) as shown in figure.

NOTE:
Put the installer so that the location of the inside mounting is visible through openings of the installer.

d) While holding bolt head of bolt set (3) in special tool, tighten nut and press-fit new rear differential rear mounting until flange (6) comes in contact with rear suspension frame (2).
Special Tool
09914-95410

NOTE:
When start to press-fit a rear differential rear mounting, check location of the mounting through openings of the installer (4) whether it is positioned as indicated in Step 2), and set again for correction if necessary.









3) Clean mounting holes in front mounting bracket (1) where rear differential front mountings come in contact with.
4) Install new rear differential rear mounting (2) of the same type as the removed mounting to front mounting bracket (1) as follows.
a) Set new rear differential front mounting (2) to front mounting bracket (1) as shown in figure.

NOTE:
Either mounting of type [A] or type [B] is installed. The type is distinguish by the shape. Distinguish between types [A] and [B] by the shape in order to install the same type of mounting.









b) Using attachment (3) in special tool and hydraulic press, install rear differential front mountings (2) to rear differential front mounting bracket (1) so as to protruding dimension "a" and "b" become as specified below.

Distance between mounting bracket and mounting
"a": 0 - 0.5 mm (0.00 - 0.01 in.) (Type A)
"b": 4.0 - 5.0 mm (0.15 - 0.19 in.) (Type B)

Special Tool
09914-95410













5) Install rear differential front bracket to rear differential and tighten its bolts to specified torque. Rear Differential Unit Components
6) Install rear differential to vehicle. Rear Differential Dismounting and Remounting
7) Fill rear differential with oil to specified level. Service and Repair