Differential: Other Suzuki Aerio I

Remounting

Reverse dismounting procedure for remounting noting the following points.

Scheme 56

1. Install propeller shaft (1) to companion flange (2) aligning match marks (3).
2. Tighten each bolt to specified torque. Tightening torque Differential front mounting bracket bolts a: 50 N.m (5.0 kg-m, 36.5 lb-ft) Differential front mounting bracket bolts b: 50 N.m (5.0 kg-m, 36.5 lb-ft) Propeller shaft flange bolts c: 23 N.m (2.3 kg-m, 17.0 lb-ft) Rear control rod outer bolts d: 90 N.m (9.0 kg-m, 65.0 lb-ft) Rear trailing rod rear bolts e: 90 N.m (9.0 kg-m, 65.0 lb-ft) Parking cable wire mounting bolts f: 10 N.m (1.0 kg-m, 7.5 lb-ft) Rear drive shaft nuts: 175 N.m (17.5 kg-m, 126.5 lb-ft) Wheel nuts: 85 N.m (8.5 kg-m, 61.5 lb-ft)
3. Pour hypoid gear oil as specified referring to «REAR DIFFERENTIAL OIL CHANGE»(ref-251076-S12430675312007032000000) .

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

1. Remove differential cover (1).
2. Remove breather plug (2) from differential cover (1).
3. Remove differential side bearing stopper and then remove differential side bearing retainer. Special Tool (A): 09923-58520
4. Using some appropriate rod (1), drive out differential side bearing outer races (2). NOTE: When driving out differential side bearing outer races, be very careful not to cause damage to tooth surface of bevel gear.
5. Remove bevel gear assembly (3).
6. Remove bevel gear bolts (1) and then remove drive bevel gear (2).
7. Remove differential side bearings (3).
8. Drive out differential side pinion shaft pin with special tool and hammer. Special Tool (B): 09922-85811 Disassemble differential side gears (2), pinions (3), washers and shaft (4) in differential case (1).
9. Remove caulking of bevel pinion nut with special tool and power wrench (1). Special Tool (C): 09930-40113
10. Remove companion flange (1) and washer from drive bevel pinion, and then drive out drive bevel pinion. Special Tool D 09913-85230 E 09913-65135
11. Remove rear bearing (2) from drive bevel pinion (1) by using bearing puller (3) and press.
12. Using a hammer and brass bar (1), drive out front bearing outer race (2).
13. Using a hammer and brass bar (1), drive out rear bearing outer race (2).

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.

Scheme 68

1. Press-fit bevel pinion bearing outer races to differential carrier (1) by using special tools as shown in figure. Special Tool 09924-74510 09951-16090

Scheme 69

Scheme 70

Scheme 71

1. After applying differential oil to side gears (4), pinions (5), pinion shaft (3), side washers (1) and pinion washers (2), install them in differential case (6). NOTE: Used left and right differential side washers are not interchangeable.
2. Check pinion gear (1) for smooth rotation.
3. Align pinion shaft hole position with differential case and drive in differential pinion shaft pin till they are flush with end surface of case. Special Tool 09922-85811
4. Apply thread lock cement to thread of bevel gear bolts (1).
5. Put bevel gear (2) on differential case (3) and fasten them with 8 bolts (1) by tightening them to specified torque. CAUTION: Use of any other bolts than that specified is prohibited.

"A": Thread lock cement 99000-32110

Tightening torque

Bevel gear bolts (a): 73 N.m (7.3 kg-m, 52.0 lb-ft)

Scheme 72

Scheme 73

Scheme 74

1. Press-fit differential side bearing (1) with special tool. Special Tool 09951-16060 09924-74510
2. Hold bearing (2) press-fitted in Step 1 with holder and press-fit differential side bearing (1) on the other side. NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing. Special Tool 09951-16060 09924-74510 09923-78210

Recommended Service Material

SERVICE MATERIAL SPECIFICATION

Note. Required service material is also described in the following. Rear Differential Components