Suzuki Grand Vitara JB627. Service manual — part 145

3B-22 Differential: Rear

Rear Differential Dismounting and Remounting

S6JB0B3226003

Dismounting

1) Lift up vehicle and drain oil from rear differential.
2) Remove rear propeller shaft referring to “Propeller

Shaft Removal and Installation in Section 3D”.

3) Remove exhaust center pipe referring to “Exhaust

System Components in Section 1K”.

4) Remove rear drive shafts referring to “Rear Drive

Shaft Assembly Removal and Installation: Rear in
Section 3A”.

5) Support rear differential with transmission jack.
6) Remove front and rear mounting bolts, and then

lower rear differential.

Remounting
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 kgf-m, 87.0 lb-ft)
Rear differential rear mounting bolt: 120 N·m (
12.0 kgf-m, 87.0 lb-ft)

• Tighten rear suspension frame front and rear bolts to

specified torque referring to “Rear Suspension
Construction in Section 2C”.

• Fill rear differential oil referring to “Rear Differential Oil

Change: Rear”.

Rear Differential Components

S6JB0B3226004

2

10

10

12

(a)

18

(a)

18

(b)

24

19

9

21

11

5

27

13

23

20

12

(c)

22

3

4

6

7

A

8

1

(a)

25

12

11

26

17

16

14

14

16

17

15

20

15

1322

28

I6JB0A322001-01

1. Universal joint flange

18. Retainer bolt

2. Hypoid gear set

19. Rear drive right retainer

: Apply sealant 99000-31260 to mating surface of right retainer,
carrier and rear cover.

3. Bevel pinion spacer

20. Shim

Differential: Rear 3B-23

Rear Differential Assembly Disassembly and
Reassembly

S6JB0B3226005

Disassembly

1) Drive out rear drive right and left shaft using special

tools.

Special tool
(A): 09942–15511
(B): 09943–17912

2) Remove rear drive right and left retainers.
3) Tapping rear cover flanges with plastic hammer,

remove rear cover (1) and dynamic damper (if
equipped).

4) Disassembly rear drive right retainer as follows, if

necessary.
a) Remove oil seal (1) using special tool.

Special tool
(A): 09913–50121

b) Remove snap ring.

4. Shim

21. Rear drive left retainer

: Apply sealant 99000-31260 to mating surface of left retainer,
carrier and rear cover.

5. Rear bearing

22. Bevel gear bolt

: Apply thread lock cement 99000-32110 to thread part of bolt.

6. Front bearing

23. Rear cover

7. Oil seal

: Apply grease 99000-25010 to oil seal lip.

24. Rear cover bolt No.2 bolt

8. Flange nut

: After tightening nut so as rotation torque of bevel pinion shaft to be in
specified value, caulk nut securely.

25. Rear cover bolt No.1 bolt

9. Differential carrier

: Apply sealant 99000-31260 to mating surface of carrier and rear cover.

26. Pinion joint

10. Differential pinion

27. Differential right case

11. Differential gear

28. Dynamic damper (if equipped)

12. Pinion shaft

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

13. Differential left case

: 60 N

⋅m (6.0 kgf-m, 43.5 lb-ft)

14. Thrust washer

: 200 N

⋅m (20.0 kgf-m, 145.0 lb-ft)

15. Differential side bearing

: Do not reuse.

16. Spring washer

: Apply differential oil.

17. Pinion washer

(A)

(B)

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1

I5JB0A322008-01

(A)

1

I5JB0A322009-01

I5JB0A322010-01

3B-24 Differential: Rear

c) Drive out rear drive shaft bearing using special

tools.

Special tool
(A): 09930–30104
(B): 09941–64511

5) Disassembly rear drive left retainer in the same

manner at Step 4), if necessary.

6) Take out differential assembly (1), outer race and

shim all at once.

7) Pull out differential side bearing (1) using special

tools.

Special tool
(A): 09913–65135
(B): 09925–86010

8) Remove drive bevel gear (hypoid gear), differential

gears, differential pinions and pinion shaft as follows.
a) 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).

b) Remove pinion shafts (1), differential gears,

washers, differential pinions, spring washers,
thrust washers and pinion joint.

9) Remove drive bevel pinion (hypoid gear) assembly

as follows.
a) Hold joint flange with special tool and then

remove flange nut by using power wrench (4 –
10 magnification) (2).

Special tool
(A): 09922–66021

(A)

(B)

I5JB0A322011-01

1

I5JB0A321012-02

1

(B)

(A)

I5JB0A321013-02

1. Socket wrench

3

2

1

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1

I5JB0A321015-02

(A)

2

1

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Differential: Rear 3B-25

b) Make mating marks (1) on drive bevel pinion and

companion flange.

CAUTION

!

Do not make mating mark on the coupling
surface of the flange.

c) Remove flange (2) from drive bevel pinion. Use

special tool if it is hard to remove.

Special tool
(A): 09913–65135
(B): 09925–88210

d) 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.

e) 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.

10) Remove oil seal (1) using special tool.

Special tool
(A): 09913–50121

11) Using a hammer and brass bar (1), drive out front

bearing outer race (2).

2

(B)

(A)

2

1

I5JB0A321017-02

3

2

1

I5JB0A321018-01

1. Drive bevel pinion

I1JA01322006-01

(A)

1

I5JB0A321019-01

I5JB0A321020-01