SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-34
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation
S6RW0D3206010
Remove and install front mounting arm and/or rear
mounting bracket after rear differential removed.
For tightening torque of each bolt and nut, refer to “Rear
Differential Mountings Components”.
Rear Mounting Bracket Assembly Disassembly
and Reassembly
S6RW0D3206011
Disassembly
Drive out mountings from rear mounting bracket using
special tool and hydraulic press.
Special tool
(A): 09913–70123
(B): 09951–26020
Reassembly
Press mountings in rear mounting bracket using special
tool and hydraulic press with caring its installation
position shown in figure.
Special tool
(A): 09913–85210
(B): 09951–26020
Rear Differential Dismounting and RemountingS6RW0D3206012
Dismounting
1) Lift up vehicle and drain oil from rear differential.
2) Remove propeller shaft referring to “Propeller Shaft
Assembly Removal and Installation in Section 3D”.
3) Remove rear drive shafts assembly referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
4) Support rear differential (3) with transmission jack
(4).
5) Remove mounting arm bolts (2) and rear mounting
bolts (1), and then lower rear differential with rear
mounting bracket.
Remounting
Reverse dismounting procedure for remounting of rear
differential, noting the following points.
• Tighten each bolt to specified torque referring to “Rear
Differential Mountings Components”.
• Fill gear oil to rear differential referring to “Rear
Differential Oil Change”.
(B)
(A)
I5RW0A320023-02
(A)
(B)
I5RW0A320024-02
3
4 21
I5RW0A320025-01

Downloaded from www.Manualslib.com manuals search engine 3B-35 Differential:
Rear Differential ComponentsS6RW0D3206013
4 5
9
2
30
6
(a)13
12
(a)
3
A
3A
141617 2118
29
3A
1(b)
22
1217G
101217G
11
8OIL
15OIL
19 20OIL
23OIL
25OIL27OIL
27OIL
25OIL
19OIL18
26 28
OIL
26OIL23OIL
24OIL
(c)
14
7
I5RW0A320026-02
1. Flange nut 13. Differential cover bolt 25. Differential gear
2. Companion flange 14. Spacer 26. Spring washer
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.15. Rear bearing 27. Thrust washer
4. Coupling front bearing 16. Shim 28. Pinion shaft
5. Coupling case
: Apply sealant 99000-31260 to mating surface of carrier and coupling
case.17. Bevel pinion 29. Pinion shaft pin
6. Coupling assembly
: Never disassemble.18. Shim 30. Coupling case bolt
7. Snap ring 19. Differential side bearing : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
8. Bevel pinion nut
: Tighten nut so as rotation torque of bevel pinion to be in specified value.20. Bevel gear : 125 N⋅m (12.5 kgf-m, 90.5 lb-ft)
9. Front bearing 21. Differential case : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
10. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear cover.22. Bevel gear bolt : Do not reuse.
11. Coupling air temperature sensor 23. Pinion washer : Apply differential oil.
12. Differential cover 24. Pinion

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-36
Rear Differential Disassembly and ReassemblyS6RW0D3206014
Disassembly
1) Remove rear mounting bracket from rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
2) Remove drive shaft flanges.
3) Separate coupling case from differential carrier using
special tool.
Special tool
: 09912–34510
4) Hold companion flange with special tool and then
remove flange nut.
Special tool
(A): 09930–40113
5) Remove companion flange (1) from pinion. Use
special tool if it is hard to remove.
Special tool
(A): 09913–651356) Remove coupling assembly (1) by using hydraulic
press.CAUTION!
Do not drop coupling assembly. If it is
dropped, replace it with a new one.

7) Disassemble coupling case as follows, if necessary.
a) Remove oil seal using special tool.
Special tool
(A): 09913–50121
b) Remove snap ring using snap ring pliers.
c) Remove bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
(A)
I5RW0A320027-01
(A)
1
I5RW0A320028-01
1
I5RW0A320029-01
(A)
I5RW0A320030-01
(A)
I5RW0A320031-01

Downloaded from www.Manualslib.com manuals search engine 3B-37 Differential:
8) Remove oil seals from rear differential (1) using
special tool.
Special tool
(A): 09913–50121
9) Remove differential cover (1) using special tool, and
then take out differential assembly, outer race and
shim all at once.
Special tool
(A): 09912–34510
10) Pull out differential side bearings (1) using special
tools.
Special tool
(A): 09913–60910
(B): 09925–88210
11) 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) Drive out differential side pinion shaft pin with
special tool and hammer.
Special tool
(B): 09922–85811
c) Disassemble differential gears (2), pinions (3),
washers and shaft (4) in differential case (1).
12) Remove bevel pinion nut with special tool.
Special tool
(A): 09927–27910
13) Remove rear bearing (2) from drive bevel pinion (1)
by using bearing puller (3) and hydraulic press.
1(A)I5RW0A320032-01
(A)
1
I5RW0A320033-01
(A)
(B)
1
I5RW0A320034-02
1
3
2
I5RW0A320035-01
I5RW0A320036-01
(A)
I5RW0A320037-04
I3RH01322026-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-38
14) Using a hammer and brass bar (1), drive out front
bearing outer race (2).
15) Using a hammer and brass bar (1), drive out rear
bearing outer race (2).
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 in the following.
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.

1) Press-fit bevel pinion bearing outer races to
differential carrier (1) by using special tools and
hydraulic press as shown in the figure.
Special tool
(A): 09913–85210
(B): 09913–75510
2) After applying differential oil to differential gears (4),
pinions (5), pinion shaft (3), side washers (1), spring
washers (7) and pinion washers (2), install them in
differential case (6).
For correct installing direction of side washers and
spring washers, refer to figure.
NOTE
Used left and right differential side washers
are not interchangeable.

3) Check pinion gear (1) for smooth rotation.
1
2
I5RW0A320038-01
1
2
I5RW0A320039-01
(B)(A)
1
I5RW0A320040-02
7 6
4
5
3
21
I5RW0A320041-01
I3RH01322031-01

Downloaded from www.Manualslib.com manuals search engine 3B-39 Differential:
4) Align holes of pinion shaft and differential case and
drive in differential pinion shaft pin till they are flush
with end surface of case.
Special tool
(A): 09922–85811
5) Put bevel gear (2) on differential case (3) and tighten
new bolts (1) to specified torque.
CAUTION!
Use of any other bolts than that specified is
prohibited.

Tightening torque
Bevel gear bolt (a): 73 N·m (7.3 kgf-m, 52.0 lb-ft)6) Press-fit differential right side bearing (1) with special
tools and hydraulic press.
Special tool
(A): 09913–80113
(B): 09926–48010
7) Hold differential right side bearing (2) with special
tool and press-fit differential left 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): 09913–80113
(B): 09926–48010
(C): 09925–88210
I5RW0A320042-01
1, (a)
23
I5RW0A320043-01
I5RW0A320044-01
I5RW0A320045-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-40
8) To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier
properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel
pinion, differential carrier and mounting dummy.
Special tool
(A): 09922–76120
(B): 09922–76250
(C): 09922–76140
(D): 09922–76420
(E): 09922–76330
(F): 09922–76150
(G): 09922–76340
(H): 09922–76530
3
2
14
5
6
(H)(B)
(A)
(C)
(D)
(E)
(G)
(F)
“a”“c”“b”
“d”
“e”
I5RW0A320046-03
1. Front bearing “a”: Pinion dummy height + Attachment height 49 mm/1.929 in.
2. Differential carrier “b”: Axle dummy radius 31 mm/1.220 in.
3. Rear bearing “a” + “b”: Mounting dummy size 80 mm/3.149 in.
4. Spacer “c”: Measured dimension
5. Drive bevel pinion “d”: Drive bevel pinion mounting distance 80 mm/3.149 in.
6. Drive bevel gear “e”: Shim size for mounting distance adjustment (“e” = “c”)

Downloaded from www.Manualslib.com manuals search engine 3B-41 Differential:
9) Set special tools and make drive bevel pinion
mounting dummy.
Special tool
(A): 09922–76120
(B): 09922–76250
10) Install dial gauge (1) to mounting dummy as shown
in figure.
Special tool set distance
“a”: 38.0 mm (1.496 in.)
“b”: 0 mm (0.000 in.)
11) Set special tools and make drive bevel pinion
dummy.
Special tool
(A): 09922–76140
(B): 09922–76420
(C): 09922–76330
(D): 09922–7634012) Apply gear oil to drive bevel pinion bearings, install
special tools with bearings to differential carrier as
shown in figure.
Special tool
(A): 09922–76140
(B): 09922–76420
(C): 09922–76330
(D): 09922–76340
(E): 09922–76150
(F): 09922–76530
NOTE
This installation requires no spacer or oil
seal.

13) Tighten bevel pinion nut (special tool) (1) so that
specified bearing preload is obtained.
NOTE
Before taking measurement, check for
rotation by hand more than 15 revolutions.

Pinion bearing preload (at 50 r/min)
: 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb-
in.)
I5RW0A320047-01
(C)
(D)
(A)
(A)(B)I5RW0A320048-01
(E) (D) (C)(B) (A) (F)I5RW0A320049-01
1
I5RW0A320050-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-42
14) Set dial gauge to bevel pinion mounting dummy and
make 0 (zero) adjustment on surface plate.
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).

15) Place zero-adjusted mounting dummy (1) and dial
gauge set on pinion dummy (2) and take
measurement between zero position and extended
dial gauge measuring tip.
NOTE
• Repeat turning back and forth of dummy
and measure distance as far as top surface
of pinion dummy accurately.
• When dial gauge measuring tip extends
from 0 (zero) position, pointer turns
counterclockwise.

16) Necessary adjusting shim thickness is the same
value as measured value by dial gauge.
17) Select adjusting shim(s) (2) closest to obtained value
from among the following available sizes and put it in
place and then press-fit rear bearing (1) to bevel
pinion (3).
Available shim thickness
0.30, 0.60, 0.63, 0.66, 0.69, 0.72, 0.75, 0.78, 0.81,
0.84 and 0.87 mm (0.012, 0.023, 0.024, 0.026,
0.027, 0.028, 0.030, 0.031, 0.032, 0.033 and 0.034
in.)
Special tool
(D): 09925–18011
18) With new pinion spacer (2) inserted as shown in
figure, install front bearing (1) to differential carrier
(3).
NOTE
Apply differential oil to front and rear
bearings.

I5RW0A320051-01
1
2
I5RW0A320052-01
Necessary shim thickness
“e”= Dial gauge measured
value “c”
I3RH01322055-01
I5RW0A320053-01

Downloaded from www.Manualslib.com manuals search engine 3B-43 Differential:
19) Using special tool and plastic hammer, drive oil seal
(2) into differential carrier (1) as shown in figure.
Then apply grease to oil seal lip.
NOTE
Install oil seal horizontally to surface of
differential carrier.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between differential carrier and oil seal
“a”
: 0.5 – 1.5 mm (0.02 – 0.06 in.)
Special tool
(A): 09913–85210
20) Tighten bevel pinion nut (1) gradually with special
tool to specified torque while turning bevel pinion.
Set bearing preload of bevel pinion to specification.
NOTE
• Before taking measurement with torque
wrench, check for smooth rotation with
turning bevel pinion 15 revolutions or
more by hand.
• Be sure to tighten gradually and carefully
till specified pinion bearing preload is
obtained. Turning back overtightened
flange nuts should be avoided.
• Measure pinion bearing preload while
turning bevel pinion about 50 rpm.
• Write down measured value of bevel pinion
bearing preload for differential side
bearing shim adjustment.

Special tool
(A): 09927–27910
Tightening torque
Bevel pinion nut: 230 – 340 N·m (23.0 – 34.0 kgf-
m, 166.5 – 246.0 lb-ft)
Bevel pinion bearing preload (Bevel pinion
rotational torque)
: 1.3 – 2.6 N⋅m (13.0 – 26.0 kgf-cm, 11.3 – 22.6 lb-
in.)
21) Install differential case assembly, bearing outer
races, removed shim and differential cover,
temporarily.
NOTE
• Used left and right outer races are not
interchangeable.
• When measuring bevel pinion bearing
preload, install differential cover with
sealant not applied.

22) Select differential side bearing shim so that bevel
pinion bearing preload may be specified value.
NOTE
Select shims so that thickness of right side
shims and left side shims become almost
even.

Bevel pinion bearing preload
Preload measured in Step 20) + 0.3 – 0.7 N⋅m (3 –
7 kgf-cm, 2.6 – 6.0 lb-in.)
Available shim thickness
0.45, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65
and 2.70 mm (0.017, 0.090, 0.092, 0.094, 0.096,
0.098, 0.100, 0.102, 0.104 and 0.106 in.)
(A)
11
2, “A”
“a”
I5RW0A320054-02
(A)
1
I5RW0A320055-03
I5RW0A320056-01