differential SUZUKI SWIFT 2000 1.G Transmission Service Owner's Guide

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

REAR DIFFERENTIAL 7F-9
7) Remove coupling case oil seal by using special tool.
Special tool
(C) : 09913-50121
INSPECTION
Check companion flange for wear of damage.
Check bearing for wear or discoloration.
Check coupling case for cracks.
Check rear differential input flange for wear damage.
ASSEMBLY
Reverse disassembly procedure for assembly, note the followings
Tighten companion flange nut to specified torque by using
special tool and caulk nut.
Tightening torque
Rear differential companion flange nut
(a) : 130 N·m (13.0 kg-m, 94.0 lb-ft)
Special tool
(A) : 09930-40113
Tighten rear differential input flange bolt (1) to specified
torque.
Tightening torque
Rear differential input flange bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Use new oil seal
Apply grease (12–15 g / 0.42–0.53 oz) to oil seal lip portion
and companion flange, where daubed in black as shown in
figure.
“A” : Grease 99000-25010
Apply grease (0.3–0.5 g / 0.01–0.02 oz) to oil seal dust lip
portion as shown in figure.
“B” : Grease 99000-25010
(C)
(a)
(A)
1, (a)

7F-10 REAR DIFFERENTIAL
REAR DIFFERENTIAL
DISASSEMBLY
1) Put identification marks (4) on differential side bearing caps
(3) and differential carrier (1).
2) Take off differential side bearing caps by removing their bolts
and remove differential gear assembly (2).
3) With aluminum plates placed on vise first, grip differential
case with it and remove drive bevel gear by removing its
bolts.
4) Using special tools, pull out differential side bearings.
Special tool
(A) : 09913-60910
(B) : 09925-88210
5) Remove differential pinion shaft.
6) Remove differential side gear, pinions and washers.
7) Uncaulk bevel pinion nut.
8) Hold differential input hub with special tool and then remove
bevel pinion nut.
Special tool
(A) : 09927-28010
9) Remove differential input hub.
NOTE:
Check number of shims and thickness of each shim in
advance.
(A)

REAR DIFFERENTIAL 7F-11
10) Remove bevel pinion (1) with rear bearing, and spacer from
carrier.
11) Remove bevel pinion rear bearing (2) by using bearing puller
(3) and press.
12) Drive out bevel pinion bearing outer race (1) by using metal-
lic stick (2).
INSPECTION
Check differential input hub for wear or damage.
Check bearings for wear or discoloration.
Check differential carrier for cracks.
Check drive bevel pinion and bevel gear for wear or cracks.
Check side gears, pinion gears and pinion shaft for wear or
damage.
Check side gear spline for wear or damage.
ADJUSTMENT AND ASSEMBLY
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 reas-
sembly according to procedures as described below.
CAUTION:
 Bevel gear and pinion must be replaced as a set when
either replacement becomes necessary.
 When replacing taper roller bearing, replace as inner
race & outer race assembly.

7F-12 REAR DIFFERENTIAL
Bevel Pinion Bearing Outer Race
For press-fitting bevel pinion bearing outer races, use special
tools as shown.
Special tool
(A) : 09924-74510
(B) : 09925-68210
(C) : 09925-98210
(D) : 09924-84510-002
Differential Case
Judging from abnormality noted before disassembly and what is
found through visual check of component parts after disassembly,
prepare replacing parts and proceed to reassembly. Make sure
that all parts are clean.
1) Assemble differential gear and measure thrust play of differ-
ential gear (2) as follows.
Special tool
(A) : 09900-20606
(B) : 09900-20701
Differential gear thrust play
: 0 – 0.37 mm (0 – 0.014 in.)
Left Side
Hold differential assembly with soft jawed vise and apply
measuring tip of dial gauge to top surface of gear (2).
Using 2 screwdrivers (1), move gear (2) up and down and
read movement of dial gauge pointer.
Right Side
Using similar procedure to the above, set dial gauge tip to
gear shoulder.
Move gear (2) up and down by hand and read dial gauge. CAUTION:
Perform press-fitting carefully so as not to tilt outer race.
[A] : Right side
[B] : Left side

REAR DIFFERENTIAL 7F-13
2) If thrust play is out of specification, select suitable side
washer from among following available size, install it and
check again that specified gear play is obtained.
Available side washer thickness
0.90, 1.00 and 1.10 mm (0.035, 0.039 and 0.043 in.)
3) Put drive bevel gear (1) on differential case (2) and fasten
them with bolts (3) by tightening them to specified torque.
Use thread lock cement for bolts (3).
“A” : Thread lock cement 99000-32110
Tightening torque
Drive bevel gear bolts (a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)
4) Press-fit differential side bearings (3) to differential case (1)
by using special tools.
Special tool
(A) : 09951-76010
(B) : 09951-16060 CAUTION:
Use of any other bolts than that specified is prohibited.
2
1 3, “A”, (a)
2. Drive bevel gear

7F-14 REAR DIFFERENTIAL
Differential Carrier
Special tool
(A) : 09922-76120
(B) : 09922-76250
(C) : 09922-76140
(D) : 09922-76430
(E) : 09922-76330
(F) : 09922-76150
(G) : 09922-76350
1) Set special tools and make drive bevel pinion mounting
dummy.
Special tool
(A) : 09922-76120
(B) : 09922-76250
2) Install dial gauge (1) to mounting dummy as shown in figure.
Special tool set distance
“a” : 25.0 mm (0.984 in.)
“b” : 0 mm (0.000 in.)
A: Pinion dummy height D: Drive bevel pinion mounting distance 68.00mm/2.67716 in. 3. Differential carrier
B: Axle dummy radius E: Shim size for mounting distance adjustment (E = C) 4. Rear bearing
A+B: Mounting dummy size 68.00mm/2.67716 in. 1. Drive bevel gear 5. Spacer
C: Measured dimension 2. Front bearing 6. Drive bevel pinion

REAR DIFFERENTIAL 7F-15
3) Set special tools and make drive bevel pinion dummy.
Special tool
(A) : 09922-76140
(B) : 09922-76430
4) Apply gear oil to drive bevel pinion bearing, install bearing to
bevel pinion dummy and then install bevel pinion dummy to
differential carrier.
5) Apply gear oil to drive bevel pinion bearing, install bearing to
special tool.
Then install them with another special tool to bevel pinion
dummy.
Special tool
(A) : 09922-76350
(B) : 09922-76150
(C) : 09922-76330
(D) : 09922-76430
(E) : 09922-76140
6) Tighten bevel pinion nut (special tool) (1) so that specified
bearing preload is obtained.
Pinion bearing preload (at 50 r/min)
(a) : 5.0 – 13.0 kg-cm (4.4 – 11.2 lb-in.)
7) Set dial gauge to bevel pinion mounting dummy and make 0
(zero) adjustment on surface plate.
NOTE:
This installation requires no spacer or oil seal.
(E)
(D)
(C)
(A)
(B)
NOTE:
Before taking measurement, check for rotation by hand
more than 15 revolutions.
NOTE:
 When setting dial gauge to mounting dummy, tighten
screw lightly. Be careful not to overtighten it, which
will cause damage to dial gauge.
 With dial gauge set, turn dummy back and forth 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).