Front & Rear Differential Assemblies: Disassembly

1. Mount differential carrier in Holding Fixture (09944-76010) and vise. Mark differential side bearing caps for installation reference. See Figure or Figure .
2. Remove side bearing lock plates and caps. Remove side bearing adjusters and outer bearing races. On rear differentials, remove rear wheel speed sensor. On front and rear differentials, remove ring gear assembly.
3. On rear differentials, separate differential left case (with rear wheel anti-lock exciter ring) from right case. Using a copper hammer, carefully remove exciter ring from left case. Tap evenly along outer edge of exciter ring.
4. On front and rear differentials, turn differential carrier in fixture 90 degrees. Using pinion Flange Holder (09922-66020), remove pinion flange nut. Remove joint flange. Remove pinion shaft. Using Oil Seal Remover (09951-18210) and slide hammer, remove pinion oil seal.
5. Remove outer pinion bearing from differential carrier. Remove outer and inner pinion bearing races. Using side bearing Puller (09913-61510) and Differential Side Bearing Remover (09913-85230), remove differential side bearings.
6. Mount differential case in vise. Using arbor punch and hammer, remove spring pin. See Fig 1 . Remove differential side gears, selective shims, pinion gears, thrust washers and shafts. Remove collapsible spacer and inner pinion bearing. Discard collapsible spacer.

Fig 1: Removing Spring Pin

Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Replace ring gear, pinion and taper roller bearings and races as a set.