Suzuki Grand Vitara JB416 / JB420. Manual — part 168

3B-25 Differential: Rear

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

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.

1

I5JB0A321012-02

1

(B)

(A)

I5JB0A321013-02

3

2

1

I5JB0A321014-02

1. Socket wrench

1

I5JB0A321015-02

(A)

2

1

I5JB0A321016-02

Differential: Rear 3B-26

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).

12) Drive out rear bearing outer race (1) in the same

manner as Step 11).

2

(B)

(A)

2

1

I5JB0A321017-02

3

2

1

I5JB0A321018-01

1. Drive bevel pinion

I1JA01322006-01

(A)

1

I5JB0A321019-01

I5JB0A321020-01

I5JB0A321021-01

3B-27 Differential: Rear

Reassembly
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.

1) For press-fitting drive bevel pinion bearing outer

races, use special tools and press as shown in the
figure.

Special tool
(A): 09924–74510
(B): 09925–14520
(C): 09913–75510

2) 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.

3) Check differential pinion gear (1) for smooth rotation.

4) 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 99000–32110 (Thread
Lock Cement Super 1322)

Tightening torque
Bevel gear bolt (a): Tighten 40 N

⋅m (4.0 kgf-m,

29.5 lb-ft) + 50

°

1. Differential carrier

(B)

(A)

1

(C)

I5JB0A321022-01

I5JB0A321023-05

1

I5JB0A322015-01

2, (a), “A”

3

1

I5JB0A321025-01

Differential: Rear 3B-28

5) 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)

6) Press-fit left side bearing (1) with special tool and

hydraulic press.

Special tool
(A): 09913–75821
(B): 09924–84510–004

7) 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
(A): 09913–75821
(B): 09924–84510–004
(C): 09924–84510–005

1. Torque wrench
3. Aluminum plate
4. Vise

I5JB0A321026-01

(B)

(A)

1

I5JB0A321027-01

(B)

(A)

1

(C)

I5JB0A321028-02