Rear Differential Disassembly - Suzuki Jimny Workshop Manual

1) Set special tool on vise (1) securely.

2) Using 2 bolts (2) and nuts (3), set differential assembly onto special tool.

3) Put match marks (7) on differential side bearing caps and differential carrier (1).

4) Remove differential side bearing lock plates (4) and differential side bearing caps (6) by removing their bolts and then remove bearing adjusters (5), side bearing outer races and drive bevel gear (2) with differential case (3).

5) Turn differential assembly together with special tool (A) by 90 degrees and grip it with vise again.

6) Hold companion flange with special tool and then remove flange nut by using power wrench (3) and socket wrench (2).

7) Make mating marks (1) on drive bevel pinion (2) and companion flange (3).

8) Remove companion flange from drive bevel pinion using special tool.

9) Remove drive bevel pinion with rear bearing, and spacer from differential 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 drive bevel pinion.

10) Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press.

11) Remove 10 bolts securing bevel gear to differential case, and separate gear from case.

12) 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.

13) Remove differential pinion shafts side gears, differential pinions and thrust washers.

14) Using special tools, extract side bearing from each differential case half.

15) Remove oil seal (1) from differential carrier by using special tool.

16) Drive out drive bevel pinion bearing outer races in differential carrier by hammering metal stick applied to them.