Rear Differential Disassembly

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Hold differential assembly securely and put identification marks (A) on differential side bearing caps (6).
Take off differential side bearing lock plates (4) and differential side bearing caps (6) by removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear with differential case.

Fig 1: Removing Differential Side Bearing Lock Plates
Courtesy of SUZUKI OF AMERICA CORP.
Remove drive bevel gear, pinion gear and pinion shaft.
1. With aluminum plates (3) placed on vise first, grip differential case with it and remove bevel gear (2) by removing its bolts (1).
  
  Fig 2: Removing Bevel Gear
  Courtesy of SUZUKI OF AMERICA CORP.
2. There are 8 bolts fastening two differential case halves together. Remove these bolts to sever right-hand case half from left-hand one, and take off right-hand one.
  Special tool
  
  (B): 09930-40113
  
  Fig 3: Removing Fastening Two Differential Case Bolts
  Courtesy of SUZUKI OF AMERICA CORP.
3. Remove pinion shaft, side gears, washers, differential pinions, spring washers, thrust washers.
Fig 4: Removing Pinion Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Using special tools ((C), (D)), pull out differential side bearings (1).
Special tool

(C): 09913-85230

(D): 09913-61510

Fig 5: Pulling Out Differential Side Bearings Using Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
Remove bevel pinion assembly.
1. Hold universal joint flange with special tool (E) and then remove flange nut by using power wrench (4-10 magnification) (2).
  Special tool
  
  (E): 09922-66020
  
  Fig 6: Holding Universal Joint Flange With Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
2. Make mating marks (1) on drive bevel pinion and companion flange.
  CAUTION: Don't make mating mark on the coupling surface of the flange.
3. Remove companion flange from pinion. Use special tool if it is hard to remove.
  Special tool
  
  (F): 09913-65135
  
  Fig 7: Removing Companion Flange From Pinion
  Courtesy of SUZUKI OF AMERICA CORP.
4. Remove bevel pinion with rear bearing, shim and spacer from carrier.
  If it is hard to remove, screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on pinion.
  
  Fig 8: Removing Bevel Pinion With Rear Bearing, Shim & Spacer From Carrier
  Courtesy of SUZUKI OF AMERICA CORP.
5. Remove bevel pinion rear bearing (2) by using bearing puller (3) and press.
Fig 9: Removing Bevel Pinion Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Using a hammer and brass bar (1), drive out front bearing outer race with bearing (2) and oil seal (3).

Fig 10: Driving Out Front Bearing Outer Race With Bearing & Oil Seal Using Hammer And Brass Bar
Courtesy of SUZUKI OF AMERICA CORP.
Drive out rear bearing outer race in the same way as in the Step 7).

Fig 11: Driving Out Rear Bearing Outer Race
Courtesy of SUZUKI OF AMERICA CORP.