2000 SUZUKI SWIFT oil

TRANSFER 7D-21
Tighten mounting bolt and mounting bracket bolts and nuts
to specified torque.
Tightening torque
Transfer rear mounting bracket nuts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Transfer mounting bolt
(b) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Transfer rear mounting bracket No.2 bolts
(c) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
Tighten transfer stiffener bolts (4) to specified torque.
Tightening torque
Transfer stiffener bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Tighten exhaust pipe bolts.
Tightening torque
Exhaust pipe bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Install right side drive shaft, refer to Section 4A.
Install propeller shaft and tighten propeller shaft bolts and
center support bolts to specified torque (refer to Section 4B).
Fill gear oil to transfer as specified, refer to OIL CHANGE of
ON-VEHICLE SERVICE.
Check oil level and leakage.
(a)
(b)
(c)
1. Transmission
2. Transfer
3. Stiffener
1. Exhaust No.1 pipe
2. Exhaust No.2 pipe
1
(a)(a)2

7D-22 TRANSFER
TIGHTENING TORQUE SPECIFICATION
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
Fastening partTightening torque
Nm kg-m lb-ft
Transfer oil level/filler and drain plugs 21 2.1 15.5
Transfer bevel gear nut 150 15.0 108.5
Transfer case bolts 23 2.3 17.0
Transfer output retainer bolts 50 5.0 36.5
Transfer mounting bolts 50 5.0 36.5
Transfer rear mounting bracket bolts 55 5.5 40.0
Transfer rear mounting bracket nuts 50 5.5 36.5
Transfer mounting bolt 55 5.5 40.0
Transfer rear mounting bracket No.2 bolts 55 5.5 40.0
Transfer stiffener bolts 50 5.0 36.5
Exhaust pipe bolts 50 5.0 36.5
MaterialRecommended SUZUKI products
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1216B
(99000-31230)Oil drain plug
Oil level plug
Mating surface of transfer case
09913-65135 09925-58210 09941-54911 09924-84510-005
Bearing puller Oil seal installer Bearing outer race
removerBearing installer attach-
ment

TRANSFER 7D-23
09913-75821 09930-40113 09913-50121 09913-75810
Bearing installer attach-
mentRotor holder Oil seal remover Bearing installer
09945-16070 09952-76011 09922-76140 09922-76150
Retainer ring installer set Snap ring pliers
(closing type)Bevel pinion shaft Bevel pinion nut
09922-76340 09922-76430 09951-16090
Rear collar Front collar Oil seal installer

REAR DIFFERENTIAL 7F-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7E
7F
7F
8B
8C
8D
8E
9
10
10A
10B
SECTION 7F
REAR DIFFERENTIAL
CONTENTS
GENERAL DESCRIPTION ............................... 7F-2
VISCOUS COUPLING .................................. 7F-2
DIAGNOSIS ...................................................... 7F-3
ON-VEHICLE SERVICE ................................... 7F-4
OIL CHANGE ................................................ 7F-4
UNIT REPAIR OVERHAUL .............................. 7F-5
DIFFERENTIAL UNIT ................................... 7F-6
UNIT DISASSEMBLY ................................... 7F-7SUB-ASSEMBLY REPAIR............................ 7F-8
VISCOUS COUPLING .............................. 7F-8
REAR DIFFERENTIAL............................ 7F-10
UNIT ASSEMBLY ....................................... 7F-20
TIGHTENING TORQUE SPECIFICATION..... 7F-20
REQUIRED SERVICE MATERIAL................. 7F-21
SPECIAL TOOL ............................................. 7F-21

7F-2 REAR DIFFERENTIAL
GENERAL DESCRIPTION
The differential assembly uses a hypoid bevel pinion and gear.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
VISCOUS COUPLING
The 4WD vehicle is equipped with a viscous coupling (1) in front of the rear differential.
The 4WD mechanism used for this vehicle distributes optimum driving force to the front and rear wheels accord-
ing to road conditions and driving conditions.

REAR DIFFERENTIAL 7F-3
DIAGNOSIS
Condition Possible Cause Correction
Gear noise
Deteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between bevel pinion
and gearAdjust and prescribed.
Improper tooth contact in the mesh between
bevel pinion and gearAdjust or replace.
Loose bevel gear securing bolts Replace or retighten.
Damaged side gear(s) or side pinion(s) Replace.
Bearing noise
(Constant noise) Deteriorated or water mixed
lubricantRepair or replenish.
(Constant noise) Inadequate or insufficient
lubricantRepair or replenish.
(Noise while coasting) Damaged bearing(s) of
bevel pinionReplace.
(Noise while turning) Damaged differential side
bearing(s)Replace.
Oil leakage
Clogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.

7F-4 REAR DIFFERENTIAL
ON-VEHICLE SERVICE
OIL CHANGE
1) Before oil change or inspection, be sure to stop engine and
set vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Remove level/filler plug (2) and drain plug (1), then drain old
oil.
4) Install new gasket to drain plug and tighten drain plug to
specified torque.
Tightening torque
Rear differential oil drain plug
(a) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
5) Fill proper amount of new gear oil as specified below
(roughly up to level hole).
6) Install new gasket to level/filler plug and tighten level/filler
plug to specified torque.
Tightening torque
Rear differential oil level/filler plug
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil
: Hypoid gear oil API GL-5
For oil viscosity, refer to the chart.
Differential oil capacity
: 0.9 liters (1.9/1.6 US/Imp. pt)
NOTE:
 It is highly recommended to use SAE 80W-90 viscosity.
 Whenever vehicle is hoisted for any other service work
than oil change, also be sure to check for oil leakage.

REAR DIFFERENTIAL 7F-5
UNIT REPAIR OVERHAUL
22 80 Nm (8.2 kg-m) 1513
17 16
15 12
14 7
22
22 2121
2020
1918 18
16 3 10 70-250 Nm (7.0-25.0 kg-m)
23 Nm (2.3kg-m)
23 Nm (2.3kg-m)
8
5
10
2611
23 Nm (2.3kg-m)
9
4
1 130 Nm(13.0 kg-m)
3
1. Companion flange nut
: After tightening nut to specified torque,
caulk nut securely.10. Drive bevel pinion nut
: After tightening nut to specified torque,
caulk nut securely.19. Differential pinion shaft
2. Companion flange 11. Viscous coupling 20. Differential pinion
3. Oil seal
: Apply grease 99000-25010 to oil seal
lip.12. Drive bevel gear (hypoid gear) 21. Differential pinion washer
4. Coupling case 13. Drive bevel pinion gear (hypoid gear) 22. Bevel gear bolt
: Apply thread lock cement 99000-
32110 to thread part of bolt.
5. Differential input hub 14. Differential case Do not reuse.
6. Bearing 15. Differential side bearing Tightening torque
7. Spacer 16. Pinion shaft bearing Apply differential oil
8. Differential carrier 17. Bevel pinion shim
9. Rear differential input flange 18. Differential gear