SUZUKI SWIFT 2000 1.G Transmission Service Workshop Manual

TRANSFER 7D-23
09913-75821 09930-40113 09913-50121 09913-75810
Bearing installer attach-
mentRotor holder Oil seal remover Bearing installer
09945-16070 09952-76011 09922-76140 09922-76150
Retainer ring installer set Snap ring pliers
(closing type)Bevel pinion shaft Bevel pinion nut
09922-76340 09922-76430 09951-16090
Rear collar Front collar Oil seal installer

7D-24 TRANSFER

REAR DIFFERENTIAL 7F-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7E
7F
7F
8B
8C
8D
8E
9
10
10A
10B
SECTION 7F
REAR DIFFERENTIAL
CONTENTS
GENERAL DESCRIPTION ............................... 7F-2
VISCOUS COUPLING .................................. 7F-2
DIAGNOSIS ...................................................... 7F-3
ON-VEHICLE SERVICE ................................... 7F-4
OIL CHANGE ................................................ 7F-4
UNIT REPAIR OVERHAUL .............................. 7F-5
DIFFERENTIAL UNIT ................................... 7F-6
UNIT DISASSEMBLY ................................... 7F-7SUB-ASSEMBLY REPAIR............................ 7F-8
VISCOUS COUPLING .............................. 7F-8
REAR DIFFERENTIAL............................ 7F-10
UNIT ASSEMBLY ....................................... 7F-20
TIGHTENING TORQUE SPECIFICATION..... 7F-20
REQUIRED SERVICE MATERIAL................. 7F-21
SPECIAL TOOL ............................................. 7F-21

7F-2 REAR DIFFERENTIAL
GENERAL DESCRIPTION
The differential assembly uses a hypoid bevel pinion and gear.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
VISCOUS COUPLING
The 4WD vehicle is equipped with a viscous coupling (1) in front of the rear differential.
The 4WD mechanism used for this vehicle distributes optimum driving force to the front and rear wheels accord-
ing to road conditions and driving conditions.

REAR DIFFERENTIAL 7F-3
DIAGNOSIS
Condition Possible Cause Correction
Gear noise
Deteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion
and gearAdjust and prescribed.
Improper tooth contact in the mesh between
bevel pinion and gearAdjust or replace.
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise
(Constant noise) Deteriorated or water mixed
lubricantRepair or replenish.
(Constant noise) Inadequate or insufficient
lubricantRepair or replenish.
(Noise while coasting) Damaged bearing(s) of
bevel pinionReplace.
(Noise while turning) Damaged differential side
bearing(s)Replace.
Oil leakage
Clogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.

7F-4 REAR DIFFERENTIAL
ON-VEHICLE SERVICE
OIL CHANGE
1) Before oil change or inspection, be sure to stop engine and
set vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Remove level/filler plug (2) and drain plug (1), then drain old
oil.
4) Install new gasket to drain plug and tighten drain plug to
specified torque.
Tightening torque
Rear differential oil drain plug
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
5) Fill proper amount of new gear oil as specified below
(roughly up to level hole).
6) Install new gasket to level/filler plug and tighten level/filler
plug to specified torque.
Tightening torque
Rear differential oil level/filler plug
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil
: Hypoid gear oil API GL-5
For oil viscosity, refer to the chart.
Differential oil capacity
: 0.9 liters (1.9/1.6 US/Imp. pt)
NOTE:
 It is highly recommended to use SAE 80W-90 viscosity.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.

REAR DIFFERENTIAL 7F-5
UNIT REPAIR OVERHAUL
22 80 Nm (8.2 kg-m) 1513
17 16
15 12
14 7
22
22 2121
2020
1918 18
16 3 10 70-250 Nm (7.0-25.0 kg-m)
23 Nm (2.3kg-m)
23 Nm (2.3kg-m)
8
5
10
2611
23 Nm (2.3kg-m)
9
4
1 130 Nm(13.0 kg-m)
3
1. Companion flange nut
: After tightening nut to specified torque,
caulk nut securely.10. Drive bevel pinion nut
: After tightening nut to specified torque,
caulk nut securely.19. Differential pinion shaft
2. Companion flange 11. Viscous coupling 20. Differential pinion
3. Oil seal
: Apply grease 99000-25010 to oil seal
lip.12. Drive bevel gear (hypoid gear) 21. Differential pinion washer
4. Coupling case 13. Drive bevel pinion gear (hypoid gear) 22. Bevel gear bolt
: Apply thread lock cement 99000-
32110 to thread part of bolt.
5. Differential input hub 14. Differential case Do not reuse.
6. Bearing 15. Differential side bearing Tightening torque
7. Spacer 16. Pinion shaft bearing Apply differential oil
8. Differential carrier 17. Bevel pinion shim
9. Rear differential input flange 18. Differential gear

7F-6 REAR DIFFERENTIAL
DIFFERENTIAL UNIT
DISMOUNTING
1) Hoist vehicle and remove wheels.
2) Drain oil from rear differential. (Refer to “OIL CHANGE” in
this section.)
3) Remove brake drum and disconnect parking brake cable
from brake back plate.
4) Remove axle shafts, refer to “REAR AXLE SHAFT AND
WHEEL BEARING REMOVAL” in Section 3E.
5) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown.
6) Remove differential carrier bolts and differential assembly
with viscous coupling case.
1. Drain plug
2. Level plug
1

REAR DIFFERENTIAL 7F-7
REMOUNTING
Reverse removal procedure for installation, noting the following.
Rear Differential
Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 9900-31110
Install differential carrier assembly to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Install propeller shaft to joint flange aligning match marks (2)
and tighten propeller shaft bolts to specified torque.
Tightening torque
Propeller shaft bolts
(b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Rear Axle Shaft
For installation of rear axle shaft, refer to “REAR AXLE SHAFT
AND WHEEL BEARING INSTALLATION” in Section 3E.
Rear Brake Drum
For installation of rear brake drum, refer to “BRAKE DRUM
INSTALLATION” in Section 5.
Differential Gear Oil
Refill differential housing with new specified oil. Refer to “OIL
CHANGE” in this section for refill.
Brake Circuit Air Purging
Make sure to purge air out of brake circuit. Refer to “BLEEDING
BRAKES” in Section 5.
Then check to ensure that joint seam of pipe is free from oil leak.
UNIT DISASSEMBLY
Remove bolts (1) and separate viscous coupling case from differ-
ential carrier.1

7F-8 REAR DIFFERENTIAL
SUB-ASSEMBLY REPAIR
VISCOUS COUPLING
DISASSEMBLY
1) Uncaulk flange nut.
2) Hold companion flange with special tool and then remove
flange nut by using power wrench.
Special tool
(A) : 09930-40113
3) Remove companion flange from pinion.
Use special tool if it is hard to remove.
Special tool
(B) : 09913-65135
4) Remove viscous coupling assembly by using hydraulic
press.
5) Remove snap ring (1) and remove bearing (2) by using
puller.
6) Remove rear differential input flange (1) from viscous cou-
pling (2).
(A)
1
2
1
2