Differential Case

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.

After applying differential oil to side gear (4), pinions (5), pinion shafts, washer, thrust washer (2) and spring washer (1), install them in differential left case (3).
For correct installing direction of thrust washer (2) and spring washer (1), refer to Fig 1 .

Fig 1: Installing Thrust Washer & Spring Washer
Courtesy of SUZUKI OF AMERICA CORP.
When installing pinion shaft No.2 (2) (shorter) into differential case and pinion, insert its "a" side into pinion joint (1).
NOTE: "a" is longer than "b". ("a" > "b")

Fig 2: Installing Pinion Shaft Into Differential Case
Courtesy of SUZUKI OF AMERICA CORP.
Check pinion gear (1) for smooth rotation.

Fig 3: Checking Pinion Gear For Smooth Rotation
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In the same manner as described in Step 1 , install thrust washer (2), spring washer (1) and side gear (4).

Fig 4: Installing Thrust Washer, Spring Washer & Side Gear
Courtesy of SUZUKI OF AMERICA CORP.
Install differential right case (1) and then tighten bolts to specified torque.
"A": Thread lock cement 99000-32020

Tightening torque

Differential case bolt (a): 41 N.m (4.1 kg-m, 30.0 lb-ft)

Fig 5: Installing Differential Right Case
Courtesy of SUZUKI OF AMERICA CORP.
Put bevel gear on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).
CAUTION: Use of any other bolts than that specified is prohibited.

"A": Thread lock cement 99000-32020

Tightening torque

Bevel gear bolt (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)

Fig 6: Tightening Differential Case Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install special tool to differential case assembly and check that preload is within specification. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special tool

(B): 09928-06010-002

Side gear preload

Max. 2.5 N m (0.25 kg-m, 1.8 lb-ft)

Fig 7: Installing Special Tool To Differential Case Assembly
Courtesy of SUZUKI OF AMERICA CORP.