rear SUZUKI SX4 2006 1.G Service Manual PDF

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 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 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-47 Differential:
31) Clean mating surface of differential carrier (1) and
coupling case (2), apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate coupling case with
differential carrier as shown in figure, and then
tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
NOTE
Install coupling pin (3) by fitting it to groove
(4) of coupling case.

32) Apply grease to oil seal lip, and then install oil seals
(1) to rear differential (2) using special tool as shown
in figure.
NOTE
Install oil seal horizontally to surface of rear
differential case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between rear differential and oil seal
“a”
: 1.0 – 2.0 mm (0.04 – 0.08 in.)
Special tool
(A): 09913–75810
33) Install drive shaft flange.
34) Install rear mounting bracket to rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
Rear Differential InspectionS6RW0D3206015
• Check companion flange 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.
1 4
3 2“A”
(a)
I5RW0A320062-04
(A)
2 21, “A”
“a”
I5RW0A320063-02

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-48
Specifications
Tightening Torque SpecificationsS6RW0D3207001
NOTE
The specified tightening torque is also described in the following.
“Rear Differential Mountings Components”
“Rear Differential Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D3208001
NOTE
Required service material is also described in the following.
“Rear Differential Components”

Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Differential oil level / filler plug 23 2.3 17.0) / )
Differential oil drain plug 23 2.3 17.0)
Coupling air temperature sensor 18 1.8 13.0)
Bevel gear bolt 73 7.3 52.0)
Bevel pinion nut 230 – 340 23.0 – 34.0 166.5 – 246.0)
Differential cover bolt 23 2.3 17.0)
Flange nut 110 11.0 79.5)
Coupling case bolt 23 2.3 17.0)
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25010) / ) / )
Sealant SUZUKI Bond No.1217G P/No.: 99000–31260) / ) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-50
09922–76150 09922–76250
Bevel pinion nut Bevel gear dummy
) / )) / )
09922–76330 09922–76340
Bevel pinion rear collar Bevel pinion rear collar
) / ) / )) / ) / )
09922–76420 09922–76530
Bevel pinion front collar Bevel pinion gauge block
) / ) / )) / )
09922–85811 09925–18011
Spring pin remover (4.5 mm) Transmission gear, bush
and bearing installer
) / ))
09925–88210 09926–48010
Bearing puller attachment Universal joint assembling
tool
) / )) / )
09927–27910 09930–40113
Holder, bevel pinion Flywheel rotor holder
) / )) / )
09951–26020 SUZUKI scan tool
Bush remover & installer
support—
) / )This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-4
• Pour transaxle oil and transfer oil referring to “Manual
Transaxle Oil Change in Section 5B” and “Transfer Oil
Change”.
Transfer Assembly ComponentsS6RW0D3306004
1
2
6
9
1110
8
7
3A
4
5
36
OIL
(a) 5
(a)
OIL
28
18
30
27
25
21
28
13
12
22OIL
OIL
32A
31A
1322(d)
34A
33
23A
2019
(c)1217G
291217G
(b)
35
15A
26
26 14
24
17
161217G(b)
A
I5RW0A330007-05
1. Transfer output flange nut
: After tightening nut so as rotational torque
of bevel pinion to be in specified value,
caulk nut securely.15. Dowel pin 29. Transfer right case
: Apply sealant 99000-31260 to
mating surface with right case.
2. Transfer output flange 16. Oil drain plug
: Apply sealant 99000-31260 to thread
part.30. Oil level / filler plug
: Apply sealant 99000-31260 to
thread part.
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.17. Transfer left case
: Apply grease 99000-25010 to left case.31. Left case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
4. Pinion shaft rear taper roller bearing 18. Transfer case bolt 32. Left case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
5. Transfer output retainer bolt 19. Reduction drive gear left bearing 33. Right case oil seal No.3
: Apply grease 99000-25010 to oil
seal lip.
6. O-ring
: Apply grease 99000-25010 to all around
surface.20. Reduction drive gear 34. Right case oil seal No.2
: Apply grease 99000-25010 to oil
seal lip.
7. Shim 21. Reduction driven gear left taper roller
bearing35. Right case oil seal No.1
: Apply grease 99000-25010 to oil
seal lip.
8. Spacer 22. Reduction driven gear right taper roller
bearing36. Transfer output retainer

Downloaded from www.Manualslib.com manuals search engine Transfer: 3C-10
Transfer Output Retainer Assembly
Disassembly and Reassembly
S6RW0D3306009
Disassembly
1) Uncaulk transfer output flange nut.
2) Remove transfer output flange nut while holding
flange (1) by using special tool.
Special tool
(A): 09930–40113
3) Remove transfer output flange (1) by bearing puller
(2).
4) Drive out bevel pinion (1) from transfer output
retainer by tapping it with plastic hammer (2).5) Drive out front taper roller bearing (1) from bevel
pinion (3) by using bearing puller (2) and hydraulic
press.
6) Remove oil seal (1) by using special tool.
Special tool
(A): 09913–50121
7) Remove rear taper roller bearing (1), pump seal (3)
and spacers (2).
8) Drive out outer races (2) (front and rear) by using
brass bar (1).
(A)
1
I5RW0A330030-01
2
1
I5RW0A330031-01
1 2
I3RH01332019-01
3
12
I5RW0A330032-01
1(A)
I3RH01332020-01
1
2
3
I5RW0A330033-03
11
2
2I5RW0A330034-01