Differential SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5B-36 Manual Transmission/Transaxle:
Differential ComponentsS6RW0D5206025
Differential Disassembly and ReassemblyS6RW0D5206026
Disassembly
1) Using special tool, remove left bearing (1).
Special tool
(A): 09913–65135
(B): 09913–852302) Using special tool, remove right bearing (1).
Special tool
(A): 09913–65135
(B): 09913–85230
(C): 09940–54950
I5RW0A520043-02
1. Differential pinion washer 6. Differential case : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
2. Differential pinion 7. Final gear : Do not reuse.
3. Differential side gear 8. Final gear bolt : Apply transaxle oil.
4. Side gear washer 9. Differential pinion shaft
5. Differential side bearing 10. Differential pinion shaft pin
(B)
(A)
1
I5RW0A520044-01
(A)
1
(B)
(C)
I5RW0A520045-01

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3) Support differential case (1) with soft jawed vise and
remove final gear bolts then take out final gear.
4) Drive out differential pinion shaft (3) pin by using
special tool and hammer and then disassemble
components parts.
Special tool
(A): 09922–85811
Reassembly
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) Install differential pinion, side gear and pinion shaft
to differential case and measure back rash and
thrust play of differential side gear as follows.
If measured value is out of specification, select
suitable side gear washer from among the following
available size, install it and check again.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09952–06010
a) Differential side gear backlash
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure.
• Fixing differential pinion, turn side gear back
and forth and read dial gauge.
Differential side gear backlash
0.10 – 0.15 mm (0.003 – 0.005 in.)
b) Differential side gear thrust play
• Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to side
gear as shown in figure.
• Move side gear up and down by hand and
read dial gauge.
Differential side gear thrust play
0.03 – 0.31 mm (0.001 – 0.012 in.)Available side gear washer thickness
2) Drive in spring pin from right side till it is flush with
differential case surface.
3) Press-fit left bearing (1) by using special tool and
hydraulic press.
Special tool
(A): 09913–70123
2. Differential side gear
I5RW0A520046-01
0.85 mm (0.033 in.) 1.05 mm (0.041 in.)
0.9 mm (0.035 in.) 1.1 mm (0.043 in.)
0.95 mm (0.037 in.) 1.15 mm (0.045 in.)
1.0 mm (0.039 in.)
2. Differential case
(B)
(B)
(C)
(A)
(A)
I5RW0A520047-01
I2RH01520074-01

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4) Press-fit right bearing (1) by using special tools and
hydraulic press.
Special tool
(A): 09925–15410
(B): 09924–07720
(C): 09913–852305) Hold differential assembly with soft jawed vise (3),
install final gear (2) and then tighten new final gear
bolts (1).
CAUTION!
Use of any other bolts than specified ones is
prohibited. Otherwise, bolts may loosen.

Tightening torque
Final gear bolt (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)
Specifications
Tightening Torque SpecificationsS6RW0D5207001
NOTE
The specified tightening torque is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Manual Transaxle Unit Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Gear Shift Shaft Components”
“Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2. Differential case
3. Differential side left bearing
I5RW0A520048-01I5RW0A520049-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Transaxle oil level / filler plug 21 2.1 15.5) / )
Transaxle oil drain plug 21 2.1 15.5)
Back up light switch 23 2.3 17.0)
Guide case bolt No.1 23 2.3 17.0)
Guide case bolt No.2 23 2.3 17.0)
Gear shift interlock bolt 23 2.3 17.0)
5th to reverse interlock guide bolt 23 2.3 17.0)
Countershaft nut 100 10.0 75.0)
Shift fork shaft bolt 10 1.0 7.5)
Side cover bolt 10 1.0 7.5)
Reverse gear shift lever bolt 23 2.3 17.0)
Transaxle case bolt 23 2.3 17.0)
Reverse shaft bolt 23 2.3 17.0)
Gear shift locating bolt 13 1.3 9.5)
Left case plate bolt 23 2.3 17.0)
Oil gutter bolt 10 1.0 7.5)
Final gear bolt 90 9.0 65.0)

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Special Tools and Equipment
Recommended Service MaterialS6RW0D5208001
NOTE
Required service material is also described in the following.
“Gear Shift Control Lever and Cable Components”
“Gear Shift and Select Shaft Assembly Components”
“Manual Transaxle Assembly Components”
“Input Shaft and Countershaft Components”
“Gear Shift Shaft Components”
“Differential Components”

Special ToolS6RW0D5208002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / ) / ) / ) /
) / ) / )
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110) / ) / ) / ) / )
09900–06107 09900–20607
Snap ring pliers (opening
type)Dial gauge
) / ) / ) / ) / ) / ))
09900–20701 09913–50121
Magnetic stand Oil seal remover
))
09913–65135 09913–70123
Bearing puller Bearing installing tool
) / )) / )
09913–75510 09913–75810
Bearing installer Bearing installer
))
09913–75821 09913–75830
Bearing installer attachment Steering pinion bush
installer
))