Differential: Removal & Installation Suzuki Equator I

INSTALLATION

Installation is in the reverse order of removal.

1. Install new side oil seals into the front final drive assembly. Refer to [ «SIDE OIL SEAL: REMOVAL AND INSTALLATION»(ref-375708-S06399039602010102800000) ]. CAUTION: Make sure there are no pinched or restricted areas on the breather hose caused by folding or bending when installing it. Fill the front final drive assembly with differential gear oil after installation.

Scheme 131

REMOVAL

Scheme 132

1. Drain the differential gear oil. Refer to [ «CHANGING DIFFERENTIAL GEAR OIL»(ref-375708-S26549271102010102800000) ].
2. Remove the rear propeller shaft. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ] (2S1330) or [ «REAR PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S12574957202010102800000) ] (2S1330-BJ100).
3. Remove the axle shaft. Refer to [ «AXLE SHAFT: REMOVAL AND INSTALLATION»(ref-375728-S06165517492010102800000) ] (C200), [ «AXLE SHAFT: REMOVAL AND INSTALLATION»(ref-375728-S06165517492010102800000) ] (M226) with or without (M226ELD).
4. Remove the stabilizer bar. Refer to [ «STABILIZER BAR: REMOVAL AND INSTALLATION»(ref-375714-S03442014722010102800000) ]
5. Disconnect the following components from the rear final drive. ABS sensor wire harness Parking brake cable Brake hoses and tubes
6. Support rear final drive assembly using a suitable jack.
7. Remove rear shock absorber lower bolts. Refer to [ «COIL SPRING AND SHOCK ABSORBER: REMOVAL AND INSTALLATION»(ref-375714-S18706460372010102800000) ].
8. Remove leaf spring U-bolt nuts. Refer to [ «LEAF SPRING: REMOVAL AND INSTALLATION»(ref-375750-S22758142892010102800000) ].
9. Remove rear final drive assembly CAUTION: Secure rear final drive assembly to the jack while removing it.

Installation is in the reverse order of removal.

Scheme 133

Scheme 134

1. Drain the differential gear oil. Refer to [ «CHANGING DIFFERENTIAL GEAR OIL»(ref-375708-S19112663932010102800000) ].
2. Remove the rear propeller shaft. Refer to [ «PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S18478494622010102800000) ] (2S1330) or [ «REAR PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S12574957202010102800000) ] (3S1330-2BJ100).
3. Remove the axle shaft. Refer to [ «AXLE SHAFT: REMOVAL AND INSTALLATION»(ref-375728-S06165517492010102800000) ]
4. Disconnect the following components from the rear final drive assembly. ABS sensor wire harness. Refer to [ «WHEEL SENSOR: REMOVAL AND INSTALLATION»(ref-375709-S15549715882010102800000) ] (Type 1) or [ «WHEEL SENSOR: REMOVAL AND INSTALLATION»(ref-375710-S00529040572010102800000) ] (Type 2) or [ «WHEEL SENSOR: REMOVAL AND INSTALLATION»(ref-375697-S19631602062010102800000) ] (Type 3). Parking brake cable Brake hoses and tubes
5. Support rear final drive assembly using a suitable jack.
6. Remove rear shock absorber lower bolts. Refer to [ «SHOCK ABSORBER: REMOVAL AND INSTALLATION»(ref-375750-S39553989062010102800000) ]
7. Remove leaf spring U-bolt nuts. Refer to [ «LEAF SPRING: REMOVAL AND INSTALLATION»(ref-375750-S22758142892010102800000) ]
8. Remove rear final drive assembly. CAUTION: Secure rear final drive assembly to the jack while removing it.

Installation is in the reverse order of removal.

Scheme 135

Note the following, and installation is in the reverse order of removal.

1. When installing differential lock control unit, tighten nuts to the specified torque. Differential lock control unit nuts: 5.1 N.m (0.52 kg-m, 45 in-lb)

Differential Lock Position Switch

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Scheme 141

1. Drain rear final drive gear oil. Refer to [ «CHANGING DIFFERENTIAL GEAR OIL»(ref-375708-S19112663932010102800000) ].
2. Remove rear propeller shaft. Refer to [ «REAR PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S12574957202010102800000) ]
3. Remove both RH and LH axle shafts. Refer to [ «AXLE SHAFT: REMOVAL AND INSTALLATION»(ref-375728-S06165517492010102800000) ]
4. Remove the carrier cover. Refer to [ «CARRIER COVER: REMOVAL AND INSTALLATION»(ref-375708-S08685204582010102800000) ].
5. Remove differential lock solenoid connector (B) bolt and disconnect differential lock position connector (A).
6. For installation, apply a paint matching mark on one side of side bearing cap. CAUTION: Side bearing caps are line-board for initial assembly. The matching marks are used to install them in their original positions. For matching mark, use paint. Do not damage side bearing cap.
7. Remove adjuster lock plates.
8. Remove side bearing caps.
9. Loosen the side bearing adjusters using Tool. Tool number: - (C - 4164)
10. Remove the differential case assembly, keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
11. Remove side bearing adjusters from gear carrier.
12. Remove bracket for the differential lock position switch connector and bolts.
13. Remove differential lock position switch.

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1. Apply sealant to threads of differential lock position switch. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove old sealant adhering to gear carrier and differential lock position switch. Also remove any moisture, oil, or foreign material adhering to application and gear carrier and differential lock position switch.
2. Install differential lock position switch on gear carrier and tighten differential lock position switch bolts with the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
3. Install side bearing adjusters into gear carrier.
4. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.
5. Apply multi-purpose grease to differential lock position connector. CAUTION: Do not reuse sensor connector.
6. Connect differential lock solenoid harness (B) and differential lock position switch connector (A). Then install it to gear carrier, tighten to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
7. Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier without tightening to specification. CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.
8. Tighten each side bearing adjusters using adjuster tool. Tool number: - (C - 4164)
9. Adjusting backlash of drive gear and drive pinion. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
10. Check total preload torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
11. Check tooth contact. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
12. Apply a bead of sealant to the mating surface of the carrier cover as shown. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
13. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to [ «CARRIER COVER: REMOVAL AND INSTALLATION»(ref-375708-S08685204582010102800000) ].
14. Installation of the remaining components is in the reverse order of removal. CAUTION: Fill the front final drive assembly with recommended differential gear oil. Refer to [ «CHANGING DIFFERENTIAL GEAR OIL»(ref-375708-S19112663932010102800000) ].

Scheme 149

Scheme 150

Scheme 151

1. Remove rear propeller shaft. Refer to [ «REAR PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S12574957202010102800000) ]
2. Remove brake calipers and rotors. Refer to [ «REAR BRAKE CALIPER AND DISC ROTOR: REMOVAL AND INSTALLATION»(ref-375743-S26817571612010102800000) ]
3. Measure the total preload torque. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ]. NOTE: Record the total preload torque measurement.
4. Remove the drive pinion nut using Tool. Tool number: KV40104000 ( - )
5. Put matching marks on the companion flange and drive pinion using paint. CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.
6. Remove the companion flange using suitable tool.
7. Remove the front oil seal using Tool. CAUTION: Do not reuse oil seal/dust shield. Tool number: ST33290001 (J-34286)

Scheme 152

Scheme 153

1. Apply multi-purpose grease to the lips of the new front oil seal. Then drive the new front oil seal in evenly until it becomes flush with the gear carrier using Tool. Tool number: ST15310000 ( - ) CAUTION: Do not reuse front oil seal. Do not incline the new front oil seal when installing. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new front oil seal.
2. Install a new oil seal/dust shield.
3. Install the companion flange to the drive pinion while aligning the matching marks.
4. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut and new drive pinion lock nut washer. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the total preload torque using Tool B. Tool number A: KV40104000 ( - ) B: ST3127S000 (J-25765-A) Total preload torque: Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. The total preload torque should be within the total preload torque specification. When not replacing the collapsible spacer, it should also be equal to the measurement taken during removal plus an additional 0.56 N.m (0.06 Kg-m, 5 in-lb). If the total preload torque is low, tighten the drive pinion lock nut in 6.8 N.m (0.69 Kg-m, 5 ft-lb) increments until the total preload torque is met. CAUTION: Do not reuse drive pinion lock nut or drive pinion lock nut washer. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. Do not loosen drive pinion lock nut to adjust the total preload torque. If the total preload torque exceeds the specifications, replace the collapsible spacer and tighten it again to adjust. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
5. Installation of the remaining components is in the reverse order of removal. CAUTION: Check the differential gear oil level after installation. Refer to [ «CHECKING DIFFERENTIAL GEAR OIL»(ref-375708-S33621480972010102800000) ].

Scheme 154

1. Drain the differential gear oil.
2. Disconnect the parking brake cable (A) and brake tube (B) from the carrier cover.
3. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface.

Scheme 155

1. Apply a bead of sealant to the mating surface of the carrier cover as shown. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
2. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
3. Connect the parking brake cable and brake tube to the carrier cover.
4. Fill the rear final drive assembly with recommended differential gear oil. Refer to [ «CHANGING DIFFERENTIAL GEAR OIL»(ref-375708-S19112663932010102800000) ].

Scheme 156

Scheme 157

1. Drain the differential gear oil. Refer to [ «CHANGING DIFFERENTIAL GEAR OIL»(ref-375708-S19112663932010102800000) ].
2. Remove the rear propeller shaft. Refer to [ «REAR PROPELLER SHAFT: REMOVAL AND INSTALLATION»(ref-375749-S12574957202010102800000) ]
3. Remove the axle shaft. Refer to [ «AXLE SHAFT: REMOVAL AND INSTALLATION»(ref-375728-S06165517492010102800000) ]
4. Disconnect the following components from the rear final drive assembly. Brake tube block connectors. Refer to [ «REAR BRAKE CALIPER AND DISC ROTOR: REMOVAL AND INSTALLATION»(ref-375743-S26817571612010102800000) ] ABS sensor wire harness. Refer to [ «WHEEL SENSOR: REMOVAL AND INSTALLATION»(ref-375709-S15549715882010102800000) ] Parking brake cable (A). Brake tube (B). Differential lock position switch harness connector (A). Differential lock solenoid harness connector (B).
5. Disconnect brake hose from brake tube at the mounting clip on top of rear final drive assembly. Then remove the metal clip to disconnect brake line from the mounting clip on top of the rear final drive assembly.
6. Support rear final drive using a suitable jack.
7. Remove rear shock absorber lower bolts. Refer to [ «SHOCK ABSORBER: REMOVAL AND INSTALLATION»(ref-375750-S39553989062010102800000) ]
8. Remove leaf spring U-bolt nuts. Refer to [ «LEAF SPRING: REMOVAL AND INSTALLATION»(ref-375750-S22758142892010102800000) ]
9. Remove rear final drive assembly. CAUTION: Secure rear final drive assembly to the jack while removing it.

Installation is in the reverse order of removal.

Scheme 158