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Differential: Component Locations Suzuki XL7 I

Differentials & Drive Axles 26 illustrations ~1381 words

Special Tools

  1. J 8092 Driver Handle
  2. J 33832 Rear Bearing Installer

Scheme 7

Scheme 7: Removal Procedure
Scheme 7: Removal Procedure

Scheme 8

Scheme 8
Scheme 8
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
  2. Drain the rear differential. Refer to «REAR AXLE LUBRICANT REPLACEMENT»(ref-268427-S37844331252007102300000) .
  3. Remove the muffler assembly. Refer to «REMOVAL PROCEDURE»(ref-268435-S28318530332007102300000) .
  4. Remove the spare tire. NOTE: In the following service procedure, it is not necessary to completely remove the propeller shaft. Relocate the propeller shaft to the side and secure with mechanics wire or equivalent.
  5. Remove the propeller shaft. Refer to «REMOVAL PROCEDURE»(ref-268433-S18162167032007102300000)
  6. Remove the left rear wheel drive shaft. Refer to «REMOVAL PROCEDURE»(ref-268434-S03869961912007102300000) .
  7. Support rear differential with a transmission jack stand.
  8. Remove the left rear differential support bushing bolt. Refer to «DIFFERENTIAL HOUSING SUPPORT BUSHING REPLACEMENT (FRONT)»(ref-268427-S34988963922007102300000) and «REMOVAL PROCEDURE»(ref-268427-S37581709752007102300000) .
  9. Lower the differential to gain access to the axle shaft seal.
  10. Using the appropriate tool, remove the axle shaft seal (1).

Scheme 9

Scheme 9: Installation Procedure
Scheme 9: Installation Procedure

Scheme 10

Scheme 10
Scheme 10
  1. Install the J 8092 to the J 33832.
  2. Using the J 8092 and the J 33832, install the axle shaft seal (1).
  3. Lift and position the differential in the rear cradle.
  4. Install the left rear support bolt.
  5. Remove the transmission jack stand.
  6. Install the left rear wheel drive shaft. Refer to «INSTALLATION PROCEDURE»(ref-268434-S34950240852007102300000) .
  7. Install the propeller shaft. Refer to «INSTALLATION PROCEDURE»(ref-268433-S18615296702007102300000) .
  8. Install the muffler assembly. Refer to «INSTALLATION PROCEDURE»(ref-268435-S41313398082007102300000) .
  9. Remove the spare tire.
  10. Fill the rear differential with fluid. Refer to «REAR AXLE LUBRICANT REPLACEMENT»(ref-268427-S37844331252007102300000) .
  1. J 8092 Driver Handle
  2. J 33832 Rear Bearing Installer

Scheme 11

Scheme 11: Removal Procedure
Scheme 11: Removal Procedure

Scheme 12

Scheme 12
Scheme 12
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
  2. Drain the rear differential. Refer to «REAR AXLE LUBRICANT REPLACEMENT»(ref-268427-S37844331252007102300000) .
  3. Remove the muffler assembly. Refer to «REMOVAL PROCEDURE»(ref-268435-S28318530332007102300000) .
  4. Remove the spare tire. NOTE: In the following service procedure, it is not necessary to completely remove the propeller shaft. Relocate the propeller shaft to the side and secure with mechanics wire or equivalent.
  5. Remove the propeller shaft. Refer to «REMOVAL PROCEDURE»(ref-268433-S18162167032007102300000) .
  6. Remove the right rear wheel drive shaft. Refer to «REMOVAL PROCEDURE»(ref-268434-S03869961912007102300000) .
  7. Support rear differential with a transmission jack stand.
  8. Remove the right rear differential support bushing bolt. Refer to «DIFFERENTIAL HOUSING SUPPORT BUSHING REPLACEMENT (FRONT)»(ref-268427-S34988963922007102300000) and «REMOVAL PROCEDURE»(ref-268427-S37581709752007102300000) .
  9. Lower the differential to gain access to the axle shaft seal.
  10. Using the appropriate tool, remove the axle shaft seal (1).

Scheme 13

Scheme 13: Installation Procedure
Scheme 13: Installation Procedure

Scheme 14

Scheme 14
Scheme 14
  1. Install the J 8092 to the J 33832.
  2. Using the J 8092 and the J 33832, install the axle shaft seal (1).
  3. Lift and position the differential in the rear cradle.
  4. Install the right rear support bolt.
  5. Remove the transmission jack stand.
  6. Install the right rear wheel drive shaft. Refer to «INSTALLATION PROCEDURE»(ref-268434-S34950240852007102300000) .
  7. Install the propeller shaft. Refer to «INSTALLATION PROCEDURE»(ref-268433-S18615296702007102300000) .
  8. Install the muffler assembly. Refer to «INSTALLATION PROCEDURE»(ref-268435-S41313398082007102300000) .
  9. Remove the spare tire.
  10. Fill the rear differential with fluid. Refer to «REAR AXLE LUBRICANT REPLACEMENT»(ref-268427-S37844331252007102300000) .

Scheme 15

Scheme 15: Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Scheme 15: Drive Pinion Flange/Yoke and/or Oil Seal Replacement
CalloutComponent Name
Preliminary Procedures Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Remove the differential clutch drum assembly. Refer to REAR WHEEL DRIVE MODULE CLUTCH HOUSING REPLACEMENT .
1Differential Pinion Seal Procedure Install a sheet metal screw into the seal. Attach a pair of pliers or a slider hammer to the screw and remove the seal. Using the slide hammer or pliers, remove the seal. Using the J 44636-1, install the pinion seal. Inspect the fluid level. Refer to REAR AXLE LUBRICANT LEVEL INSPECTION . Tip: The pinion flange, the nut and the dust cover are NOT SERVICED separately. These items are serviced with the differential clutch drum assembly. Special Tools J 44636-1 Front Output Shaft Seal Installer

PROCEDURE TABLE

Scheme 16

Scheme 16: Removal Procedure
Scheme 16: Removal Procedure

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
  2. Drain the rear differential, if needed. Refer to «REAR AXLE LUBRICANT REPLACEMENT»(ref-268427-S37844331252007102300000) .
  3. Remove the spare tire.
  4. Remove the muffler assembly. Refer to «MUFFLER REPLACEMENT»(ref-268435-S24439614992007102300000) .
  5. Remove the rear wheel drive shafts. Refer to «REMOVAL PROCEDURE»(ref-268434-S03869961912007102300000) .
  6. Remove the propeller shaft from the vehicle. Refer to «REMOVAL PROCEDURE»(ref-268433-S18162167032007102300000) .
  7. Remove the rear wheel drive module clutch housing. Refer to «REAR WHEEL DRIVE MODULE CLUTCH HOUSING REPLACEMENT»(ref-268427-S28489796312007102300000) .
  8. Support the rear differential with a transmission jack stand.
  9. Remove the rear differential support bushing bolts.
  10. Remove the front mounting nuts for the rear differential (3).
  11. Lower the rear differential to gain access rear differential clutch control module.
  12. Remove the small electrical connector from the control module (1).
  13. Remove the large electrical connector from the control module (2).
  14. Remove the rear differential assembly from the vehicle.

Scheme 19

Scheme 19: Installation Procedure
Scheme 19: Installation Procedure

Note. When positioning the rear differential assembly in the rear cradle, leave enough room to access the clutch control module.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Position the rear differential assembly in the rear cradle.
  2. Install the small electrical connector (1).
  3. Install the large electrical connector (2). NOTE: When installing the front mounting bolts tighten by hand.
  4. Install the front mounting nuts (3).
  5. Install the rear differential support bushing bolts.
  6. Raise the rear differential assembly into place. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
  7. Tighten the front mounting nuts. Tightening torque Tighten the nuts to 122 N.m (90 lb ft).
  8. Tighten the rear differential support bushing bolts. Tightening torque Tighten the nuts to 188 N.m (139 lb ft).
  9. Remove the transmission jack stand.
  10. Install the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-268433-S15569927572007102300000) .
  11. Install the rear wheel drive shafts. Refer to «INSTALLATION PROCEDURE»(ref-268434-S34950240852007102300000) .
  12. Install the rear wheel drive module clutch housing. Refer to «REAR WHEEL DRIVE MODULE CLUTCH HOUSING REPLACEMENT»(ref-268427-S28489796312007102300000) .
  13. Install the muffler assembly. Refer to «INSTALLATION PROCEDURE»(ref-268435-S41313398082007102300000) .
  14. Install the spare tire.
  15. Fill the rear differential assembly with fluid, if drained. Refer to «REAR AXLE LUBRICANT REPLACEMENT»(ref-268427-S37844331252007102300000) .
  16. Lower the vehicle.

Scheme 22

Scheme 22: Differential Housing Support Bushing Replacement (Front)
Scheme 22: Differential Housing Support Bushing Replacement (Front)
CalloutComponent Name
Preliminary Procedure Remove the Rear Differential Module. Refer to DIFFERENTIAL HOUSING SUPPORT BUSHING REPLACEMENT (FRONT) and REMOVAL PROCEDURE .
1Rear Differential Mount Bushing Tip: Use the appropriate tool to remove the bushing.

PROCEDURE TABLE

Special Tool

J-45725 Cradle Bushing Replacer

Scheme 23

Scheme 23: Removal Procedure
Scheme 23: Removal Procedure

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
  2. Remove the rear differential assembly. Refer to «REMOVAL PROCEDURE»(ref-268427-S32999856412007102300000) .
  3. Mark a reference point on the frame and old bushing at the 12 and 6 o'clock position to use to alignment the new bushing.
  4. Position the J-45725-1A (1) on the bushing (2).
  5. Position the J-45725-2A (1) on the frame. NOTE: Apply a small amount of grease on the threaded rod to lubricate the nuts when turning the nuts.
  6. Install the threaded rod, bearing and washers.
  7. Adjust the nuts so that they are touching the J-45725-1A (2) and the J-45725-2A (1).
  8. Install the proper size wrenches on the nuts. NOTE: In the following service procedure, use only HAND TOOLS when using the J-45725.
  9. While holding the front wrench (1) rotate the rear wrench (2) to remove the bushing.
  10. Remove the special tools.
  11. Remove the bushing from the frame.

Scheme 28

Scheme 28: Installation Procedure
Scheme 28: Installation Procedure

Note. Failure to perform the following service procedure prior to the installation of the new bushing, could cause premature failure of the bushing.

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Before the installation of the new bushing, use a straight edge draw a line on the new bushing at the 12 and 6 o'clock positions. Ensure that the grooves (1) are at the 12 and 6 o'clock positions.
  2. Position the new bushing so that the reference marks on the frame and the bushing are in alignment. This will ensure that the new bushing will be within the + or - 5° specification required for the proper alignment of the bushing. NOTE: The following procedure is to temporarily hold the new bushing in place so that the special tools can be installed for the proper installation. This is NOT to be used to install the bushing.
  3. Using a block of wood and a hammer, slightly tap the bushing into the frame.
  4. Assemble the threaded rod, bearings and washers as indicated in step 7 in the removal procedure.
  5. Position the J-45725-4 (2) on the inside of the frame.
  6. Position J-45725-1A (1) on the outside of the frame.
  7. Adjust the nuts so that they are touching the J-45725-2 (1) and the J-45725-2A (2).
  8. While holding the front wrench (2) rotate the rear wrench (1) to install the bushing.
  9. Remove the special tools.
  10. Install the rear differential assembly. Refer to «INSTALLATION PROCEDURE»(ref-268427-S29070634372007102300000) .
  11. Lower the vehicle.

Scheme 31

Scheme 31: Rear Differential Clutch Control Module Replacement
Scheme 31: Rear Differential Clutch Control Module Replacement
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE . Remove the spare tire. Remove the muffler assembly. Refer to REMOVAL PROCEDURE . Remove the rear differential assembly. Refer to REMOVAL PROCEDURE .
1Screws, Clutch Drum Control Module (Qty: 2). CAUTION: Refer to FASTENER NOTICE . Tightening torque Tighten screws 10 N.m (89 lb in).
2Connectors, Clutch Drum Control Module.
3Module, Clutch Drum Control. Procedure Differential Clutch Control Module Calibration. Refer to REAR DIFFERENTIAL CLUTCH CONTROL MODULE CALIBRATION .
CAUTION
Refer to FASTENER NOTICE .

PROCEDURE TABLE

After rear differential clutch control module (CCM) replacement, the following calibration procedure must be performed.

  1. Install a scan tool.
  2. Turn ON the ignition, with the engine OFF.
  3. Select Special Functions, Rear Drive System, CCM RDS Matching ID, follow instruction on the Tech 2. The CCM RDS Matching ID number can be found on the CCM harness connector.
  4. Cycle the ignition OFF, then start the engine and allow to run for 1 minute. Verify the rear differential system is functioning properly.
  5. After the calibration procedure, clear all DTC, and preform the «DIAGNOSTIC SYSTEM CHECK - VEHICLE DIAGNOSTIC INFORMATION»(ref-268408-S06696600922007102300000) .

Special Tools - Rear Drive Axle

SPECIAL TOOLS Illustration Tool Number/Description J-8092 Driver Handle J-33832 Output Shaft Seal Installer J-44636-1 Pinion Seal Installer J-45725-A Frame Bushing Installer

Scheme 32

Scheme 32: Special Tools - Rear Drive Axle
Scheme 32: Special Tools - Rear Drive Axle

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