Dismounting

Lift up vehicle and drain oil from rear differential.
Remove rear propeller shaft referring to «PROPELLER SHAFT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/driveshaft-universal-joints/#propeller-shaft) .
Remove exhaust center pipe referring to «EXHAUST SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2005-2008/remont/exhaust/#engine-exhaust-system) .
Remove rear drive shafts referring to «REAR DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/axle-shafts/#drive-shaft-axle) :Rear.
Support rear differential with transmission jack.
Remove front and rear mounting bolts, and then lower rear differential.

Reverse dismounting procedure for remounting noting the following.

Tighten rear differential mounting front and rear bolts to specified torque. Tightening torque Rear differential front mounting bolt: 120 N.m (12.0 kg-m, 87.0 lb-ft) Rear differential rear mounting bolt: 120 N.m (12.0 kg-m, 87.0 lb-ft)
Fill rear differential oil referring to «REAR DIFFERENTIAL OIL CHANGE:REAR»(/suzuki/grand-vitara/ii-2005-2008/remont/differentials-drive-axles/#differential) .

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Scheme 88: Rear Differential Components

Scheme 89

Scheme 89: Disassembly

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Drive out rear drive right and left shaft using special tools. Special Tool 09942-15511 09943-17912
Remove rear drive right and left retainers.
Tapping rear cover flanges with plastic hammer, remove rear cover (1) and dynamic damper (if equipped).
Disassembly rear drive right retainer as follows, if necessary. Remove oil seal (1) using special tool. Special Tool 09913-50121 Remove snap ring. Drive out rear drive shaft bearing using special tools. Special Tool 09930-30104 09941-64511
Disassembly rear drive left retainer in the same manner at Step 4 , if necessary.
Take out differential assembly (1), outer race and shim all at once.
Pull out differential side bearing (1) using special tools. Special Tool 09913-65135 09925-86010
Remove drive bevel gear (hypoid gear), differential gears, differential pinions and pinion shaft as follows. With aluminum plates (2) placed on vise first, grip differential case with it and remove drive bevel gear (hypoid gear) (3) by removing its bolts (1). Remove pinion shafts (1), differential gears, washers, differential pinions, spring washers, thrust washers and pinion joint.
Remove drive bevel pinion (hypoid gear) assembly as follows. Hold joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2). Special Tool 09922-66021 Make mating marks (1) on drive bevel pinion and companion flange. CAUTION: Do not make mating mark on the coupling surface of the flange. Remove flange (2) from drive bevel pinion. Use special tool if it is hard to remove. Special Tool 09913-65135 09925-88210 Remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier. If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut with a plastic hammer but never directly on drive bevel pinion. Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press. CAUTION: To avoid rear bearing from being damaged, support it at flat side of bearing puller.
Remove oil seal (1) using special tool. Special Tool 09913-50121
Using a hammer and brass bar (1), drive out front bearing outer race (2).
Drive out rear bearing outer race (1) in the same manner as Step 11 .

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.

CAUTION

Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary. When replacing taper roller bearing, replace as inner race and outer race assembly.

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For press-fitting drive bevel pinion bearing outer races, use special tools and press as shown in the figure. Special Tool 09924-74510 09925-14520 09913-75510
After applying differential oil to differential gear (4), pinions (5), pinion shafts (6), pinion washer, thrust washer (2) and spring washer (1), install them in differential right case (3). For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.
Check differential pinion gear (1) for smooth rotation.
Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2). CAUTION: Use of any other bolts than that specified is prohibited. "A": Thread lock cement 99000-32110Thread Lock Cement Super 1322 Tightening torque Bevel gear bolt a: 200 N.m (20.0 kg-m, 145.0 lb-ft)
Install special tool to differential case assembly (2) and check differential gear for preload. If preload exceeds specified value, check if foreign matter is caught or gear is damaged. Special Tool (B): 09928-06510 Differential gear preload Max. 2.5 N.m (0.25 kgf-m, 1.8 lb-ft)
Press-fit left side bearing (1) with special tool and hydraulic press. Special Tool 09913-75821 09924-84510-004
Press-fit right side bearing (1) with special tools and hydraulic press. NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing. Special Tool 09913-75821 09924-84510-004 09924-84510-005
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy. Special Tool 09900-20607 09926-78320 09922-75222 09951-16070 09951-46010 09926-78311-002 09922-76520
Install special tools with bearings (3) and flange (2) to differential carrier (1). NOTE: This installation requires no spacer or oil seal. Special Tool (E): 09951-46010 (F): 09926-78311-002
Tighten flange nut (1) so that specified bearing preload is obtained. NOTE: Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of differential oil to bearings. On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds. Special Tool (C): 09922-75222 (F): 09926-78311-002 Pinion bearing preload 0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.) Spring measure reading with special tool 20 - 40 N (2.0 - 4.0 kg, 4.4 - 8.8 lb)
Set dial gauge to mounting dummy and make 0 (zero) adjustment on surface plate (1). NOTE: When setting dial gauge to mounting dummy, tighten screw (2) lightly. Be careful not to overtighten it, which will cause damage to dial gauge. With dial gauge set, turn dummy back and force 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 09900-20607 09926-78320
Place zero-adjusted mounting dummy and dial gauge set on pinion mounting 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. Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer. Special Tool (A): 09900-20607 (B): 09926-78311 (D): 09951-16070 (F): 09926-78311-002 : 09922-76520
Obtain adjusting shim thickness by the following equation.
Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit rear bearing (1). Special Tool (G): 09913-85210 (H): 09940-53111 Available shim thickness 1.00, 1.03, 1.06, 1.09, 1.12, 1.15, 1.18, 1.21,1.24, 1.27, 1.30 and 0.3 mm (0.039, 0.040, 0.042, 0.043, 0.044, 0.045, 0.046, 0.047 0.048, 0.049, 0.050 and 0.012 in.)
With new pinion spacer (3) inserted as shown in the figure, install front bearing (5) to differential carrier (4). NOTE: Make sure to use new spacer for reinstallation. Apply differential oil to bearings.
Using special tool and plastic hammer, drive oil seal (2) into differential carrier (1) as shown in figure. Then apply grease "A" to oil seal lip. "A": Grease 99000-25010SUZUKI Super Grease A Special Tool 09951-18210
While tightening flange nut gradually with special tool and power wrench (4 - 10 magnification) (1), set preload of pinion to specification. NOTE: Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand. On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds. 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 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in.) Spring measure reading with special tool 20 - 40 N (2.0 - 4.0 kg, 4.4 - 8.8 lb) Special Tool 09922-75222 09922-66021
Select differential side bearing shim as follows. Measure dimension "a" and "b" using vernier caliper. Calculate dimension "a"-"b", and select shims from among following available size so that total of thickness of right side and left side shims may reach the calculated value. NOTE: Select shims so that thickness of right side shims and left side shims become almost even. Available shim thickness Right side: 1.75, 1.85, 1.95, 2.00, 2.05, 2.15 and 2.25 mm (0.069, 0.073, 0.077, 0.079, 0.081, 0.085 and 0.089 in.) Left side: 2.75, 2.85, 2.95, 3.00, 3.05, 3.15 and 3.25 mm (0.108, 0.112, 0.116, 0.118, 0.120, 0.124 and 0.128 in.)
To measure bevel gear backlash, set dial gauge (1) at right angle to bevel gear tooth, fix drive bevel pinion and read dial gauge while moving bevel gear. Special Tool 09900-20607 09900-20701 NOTE: Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth. Measure at least 4 points on drive bevel gear periphery.
Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
Install case assembly (1) in carrier (2).
As final step, check gear tooth contact as follows. After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc. Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact. Bring painted part up and check contact pattern, referring to the following table. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table. NOTE: Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check. TOOTH CONTACT PATTERN CHART Tooth Contact Pattern Diagnosis and Remedy Normal High Contact Pinion is positioned too far from the center of drive bevel gear (1). Increase thickness of pinion (2) height adjusting shim and position pinion closer to gear center. Adjust drive bevel gear backlash to specification. Low Contact Pinion is positioned too close to the center of drive bevel gear (1). Decrease thickness of pinion (2) height adjusting shim and position pinion farther from gear center. Adjust drive bevel gear backlash to specification. If adjustment is impossible, replace differential carrier. Check seating of bevel gear or differential case. (Check bevel gear for runout.) If adjustment is impossible, replace drive bevel gear and pinion set or differential carrier. Replace drive bevel gear and pinion set or differential case.
Upon completion of gear tooth contact check in Step 22 , caulk flange nut (2) with caulking tool (1) and hammer.
Clean mating surface of differential carrier (2) and rear cover (1), apply sealant to carrier as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate rear cover with differential carrier, and then tighten bolts to specified torque. "A": Sealant 99000-31260SUZUKI Bond No.1217G Tightening torque Rear cover bolt No. 1 (for 4WD model) a: 50 N.m (5.0 kg-m, 17.0 lb-ft) Rear cover bolt No. 1 (for 2WD model) a: 23 N.m (2.3 kg-m, 17.0 lb-ft) Rear cover bolt No. 2 b: 85 N.m (8.5 kg-m, 61.5 lb-ft)
Assembly rear drive right retainer as follows. Install rear drive shaft bearing (1) using special tool and press (2). Special Tool 09913-75520 Install snap ring. Install oil seal using special tools as shown in figure. Distance between retainer surface and oil seal "a": 2.5 - 3.0 mm (0.10 - 0.12 in.) Special Tool 09924-74510 09951-16090
Assembly rear drive left retainer in the same manner at Step 25 ) in this assembly procedure.
Clean mating surface of right retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate right retainer with carrier and rear cover, and then tighten bolts to specified torque. "A": Sealant 99000-31260SUZUKI Bond No.1217G Tightening torque Retainer bolt: 50 N.m (5.0 kg-m, 36.5 lb-ft)
Clean mating surface of left retainer, carrier (1) and rear cover (2), apply sealant to carrier and rear cover as shown in figure by such amount that its section is 1.5 mm (0.059 in.) in diameter, mate left retainer with carrier and rear cover, and then tighten bolts to specified torque. "A": Sealant 99000-31260SUZUKI Bond No.1217G Tightening torque Retainer bolt: 50 N.m (5.0 kg-m, 36.5 lb-ft)
Install rear drive right and left shaft using plastic hammer.

Refer to FRONT DIFFERENTIAL INSPECTION:FRONT .

Fastening part	Tightening torque
Fastening part	N.m	Kgf-m	Lb-ft
Rear differential front mounting bolt	120	12.0	87.0
Rear differential rear mounting bolt	120	12.0	87.0
Bevel gear bolt	200	20.0	145.0
Rear cover bolt No. 1 (for 4WD model)	50	5.0	17.0
Rear cover bolt No. 1 (for 2WD model)	23	2.3	17.0
Rear cover bolt No. 2	85	8.5	61.5
Retainer bolt	50	5.0	36.5

TIGHTENING TORQUE SPECIFICATIONS

Note. The specified tightening torque is also in REAR DIFFERENTIAL COMPONENTS .

Material	SUZUKI recommended product or Specification
Grease	SUZUKI Super Grease	P/N: 99000-25010
Sealant	SUZUKI Bond No.1217G	P/N: 99000-31260
Thread lock cement	Thread Lock Cement Super 1322	P/N: 99000-32110

SERVICE MATERIAL SPECIFICATION

Note. Required service material is also found in REAR DIFFERENTIAL COMPONENTS .

SPECIAL TOOL SPECIFICATION 09900-20607 09900-20701 Dial gauge Magnetic stand 09913-50121 09913-65135 Oil seal remover Bearing puller 09913-75510 09913-75520 Bearing installer Bearing installer 09913-75821 09913-85210 Bearing installer attachment Bearing installer 09922-66021 09922-75222 Flange holder Differential gear preload adjuster 09922-76520 09924-74510 Bevel pinion gauge block Bearing and oil seal handle 09924-84510-004 09924-84510-005 Bearing installer attachment Bearing installer attachment (D) 09925-14520 09925-86010 Bearing and oil seal installer (80 x 50 mm) Bearing puller attachment 09925-88210 09926-78311-002 Bearing puller attachment Pinion mounting dummy 09926-78311 09926-78320 Differential bevel pinion dummy Mounting dummy 09928-06510 09930-30104 Differential torque checking tool Sliding shaft 09940-53111 09941-64511 Differential side bearing installer Bearing and oil seal remover (30 mm Min.) 09942-15511 09943-17912 Sliding hammer Wheel hub remover 09951-16070 09951-16090 Shim adjuster attachment Oil seal installer 09951-18210 09951-46010 Oil seal remover & installer No. 2 Drive shaft oil seal installer