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Differential: Overview Suzuki Aerio I

Differentials & Drive Axles 22 illustrations ~1264 words

Whenever vehicle is hoisted for any other service work than oil change, also be sure to check for oil leakage.

The differential assembly uses a hypoid bevel pinion and gear.

The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between hypoid bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.

Scheme 1

Scheme 1: Rear Differential Description
Scheme 1: Rear Differential Description
ConditionPossible CauseAction
Gear noiseDeteriorated or water mixed lubricantRepair and replenish
Inadequate or insufficient lubricantRepair and replenish
Maladjusted backlash between bevel pinion and gearAdjust as prescribed
Improper tooth contact in the mesh between bevel pinion and gearAdjust or replace
Loose bevel gear securing boltsReplace or retighten
Damaged side gear(s) or side pinion(s)Replace
Bearing noise(Constant noise) Deteriorated or water mixed lubricantRepair and replenish
(Constant noise) Inadequate or Insufficient lubricantRepair and replenish
(Noise while coasting) Damaged bearing(s) of bevel pinionReplace
(Noise while turning) Damaged differential side bearing(s)Replace
Oil leakageClogged breather plugClean
Worn or damaged oil sealReplace
Excessive oilAdjust oil level

REAR DIFFERENTIAL SYMPTOM DIAGNOSIS CHART

Note. It is highly recommended to use SAE 80W-90 viscosity.

Scheme 2

Scheme 2: Rear Differential Oil Change
Scheme 2: Rear Differential Oil Change

Scheme 3

Scheme 3
Scheme 3
  1. Before oil change or inspection, be sure to stop engine and set vehicle horizontally.
  2. Check oil level and existence of leakage. If leakage is found, correct its cause.
  3. Remove level / filler and drain plugs, then drain old oil.
  4. Apply sealant to thread of drain plug (2), if reused.
  5. Tighten drain plug (2) to specified torque. "A": Sealant 99000-31110 Tightening torque Oil drain plug (b): 21 N.m (2.1 kg-m, 15.5 lb-ft)
  6. Pour proper amount of new gear oil as specified in the following (roughly up to level hole).
  7. Apply sealant to thread of level / filler plug (1) if reused.
  8. Tighten level / filler plug (1) to specified torque, after applying sealant to its thread. "A": Sealant 99000-31110 Tightening torque Oil level / filler plug (a): 21 N.m (2.1 kg-m, 15.5 lb-ft) Specified gear oil: Hypoid gear oil API GL-5 SAE 80W-90 Oil capacity: 0.7 liters (1.5/1.2 US/lmp. pt)

Scheme 4

Scheme 4: Removal
Scheme 4: Removal
  1. Hoist vehicle.
  2. Remove mounting bracket bolts (1), mounting bolt (2), nut (3) and differential front mounting (4).
  3. Drive mounting out with special tools and hydraulic press (1). Special Tool 09951-16080 09951-26020

Scheme 5

Scheme 5: Installation
Scheme 5: Installation

Scheme 6

Scheme 6
Scheme 6
  1. Press mounting in front mounting bracket (1) by using special tools and hydraulic press (2) with caring its installation position shown in figure. Special Tool 09951-16080 09951-26020
  2. Install differential front mounting (1), and tighten mounting bracket bolts (2) and mounting nut (3) 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 nut (b): 80 N.m (8.0 kg-m, 58.0 lb-ft)

Scheme 7

Scheme 7: Removal
Scheme 7: Removal

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9
  1. Hoist vehicle.
  2. Remove stabilizer bar mount bolt (1) and stabilizer bar bracket (2) installed on right side of vehicle.
  3. Place jack (1) under rear differential.
  4. Remove mounting bracket bolts (2), mounting bolts (3) and differential rear mounting (4).
  5. Drive mountings out with special tools and hydraulic press (1). Special Tool C 09951-16080 D 09951-26020

Scheme 10

Scheme 10: Installation
Scheme 10: Installation

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Press mountings (1) in rear mounting bracket (2) by using special tools and hydraulic press (3) with caring its installation position shown in figure. Special Tool C 09951-16080 D 09951-26020
  2. Install differential rear mounting (4), and tighten mounting bracket bolts (5) and mounting bolts (6) 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 bolt (b): 80 N.m (8.0 kg-m, 58.0 lb-ft)
  3. Install stabilizer bar bracket (1) and tighten stabilizer bar mount bolt (2) to specified torque. Tightening torque Stabilizer bar mount bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)

Scheme 13

Scheme 13: Dismounting
Scheme 13: Dismounting

Scheme 14

Scheme 14
Scheme 14
  1. Hoist vehicle and remove wheels.
  2. Drain oil from rear differential. Refer to «REAR DIFFERENTIAL OIL CHANGE»(ref-251076-S12430675312007032000000) .
  3. Remove parking brake wire mounting bolt (1), rear control rod outer bolts (2) and rear trailing rod rear bolt (3).
  4. Remove rear drive shafts referring to «REAR DRIVE SHAFT REMOVAL AND INSTALLATION»(ref-251075-S28182788412007032000000) .
  5. Place jack (4) so that differential assembly will not tilt.
  6. Apply match marks (6) to companion flange (7) and propeller shaft (3).
  7. Remove 4 propeller shaft flange bolts (1) from rear differential, and then pull out propeller shaft (3) from rear differential.
  8. Remove differential front mounting bracket bolts (2).
  9. Remove differential rear mounting bracket bolts (5).
  10. Lower jack (4) with rear differential assembly.

Description

To mesh bevel pinion and gear correctly, it is required to install bevel pinion to differential carrier properly by using adjusting shim as described on following steps. Shown in this figure are relative positions of bevel pinion, differential carrier and mounting dummy.

Special Tool

Scheme 15

Scheme 15: Description
Scheme 15: Description
  1. 09900-20606
  2. 09922-77280
  3. 09922-75222

Scheme 16

Scheme 16: Adjustment
Scheme 16: Adjustment

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22
  1. Install bevel pinion dummy with front and rear bearings into differential carrier and then tighten 36 mm nut (Spare parts No. 09159-28002) (1) lightly by hand. Special Tool (B): 09922-77280 Install companion flange (4) to bevel pinion dummy. Install special tool to companion flange (4) by using 4 flange bolts (2). Special Tool (C): 09922-75222
  2. Tighten 36 mm nut (1) while turning dummy about 50 RPM so that specified bearing preload is obtained. NOTE: This installation requires no spacer or oil seal. Before taking measurement with special tool, apply thin coat of differential oil to bearings and turn bevel pinion dummy 15 revolutions or more to ensure its good fitting. Pinion bearing preload (Pinion dummy rotational torque) 5.0 - 13.0 kg-cm (4.4 - 11.2 lb-in) Rotational force with special tool and spring balance 1.0 - 2.6 kg (2.2 - 5.7 lb)
  3. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate (1) by screw (2). Special Tool 09900-20606 09922-77280
  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 force 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. Special Tool 09900-20606 09922-77280
  5. Necessary adjusting shim thickness is the same valve as measured value by dial gauge. Necessary shim thickness "e" = Dial gauge measured value "c"
  6. Select adjusting shim (2) closest to obtained value from among following available sizes and put it in place and then press-fit rear bearing (1) to bevel pinion (3). Available shim thickness 0.30, 0.87, 0.84, 0.81, 0.78, 0.75, 0.72, 0.69, 0.66, 0.63 and 0.60 mm (0.012, 0.034, 0.033, 0.032, 0.031, 0.029, 0.028, 0.027, 0.026, 0.025 and 0.024 in.) Special Tool (D): 09925-18011
  7. Using special tool and plastic hammer, drive oil seal into front case (1) till it becomes flush with front case end. Then apply grease to oil seal lip. : Grease 99000-25010 Special Tool (E): 09913-85210
  8. With new pinion spacer (2) inserted as shown in figure, install front bearing (4) to differential carrier (3). NOTE: Apply differential oil to front and rear bearings.
  9. Install washer (5) to bevel pinion (1).
  10. After applying sealant to mating surface of front case (6), install it to differential carrier (3). "A": Sealant 99000-31110 Tightening torque Front case bolts: 23 N.m (2.3 kg-m, 17.0 lb-ft)
  11. Install companion flange (2) to bevel pinion and tightening bevel pinion nut gradually with special tool and power wrench (1) to specified torque while turning bevel pinion. Set bearing preload of bevel pinion to specification. NOTE: Before taking measurement with spring balance, 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. Special Tool (E): 09922-75222 (F): 09930-40113 Tightening torque Bevel pinion nut: 100 - 300 N.m (10.0 - 30.0 kg-m, 72.5 - 217.0 lb-ft) (Reference) Bevel pinion bearing preload (Bevel pinion rotational torque): 5 - 13 N.m (0.5 - 1.3 kg-m, 4.4 - 11.2 lb-ft) Rotational force with special tool: 1 - 2.6 N.m (0.1 - 0.26 kg-m, 2.2 - 5.7 lb-ft)

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