2000 SUZUKI SWIFT shaft

TRANSFER 7D-15
3) Install bevel pinion shaft with new pinion shaft spacer (1) to
transfer output retainer.
4) Press-fit pinion shaft bearing (rear side) (2) by using special
tool (and press).
Special tool
(A) : 09913-75810
5) Drive in oil seal (1) by using special tools and apply grease
to oil seal lip.
Special tool
(A) : 09913-75810
(B) : 09951-16090
“A” : Grease 99000-25010
Transfer bevel pinion shaft oil seal installing depth
“a” : 27.0 – 27.5 mm (1.063 – 1.083 in.)
6) Install flange (2) and tighten flange nut gradually so as rota-
tion torque of bevel pinion shaft to be in specified value.
Special tool
(A) : 09930-40113
Rotation torque for bevel pinion shaft
(b) : 0.5 – 1.3 N·m (0.05 – 0.13 kg-m, 0.30 – 0.90 lb-ft)
7) Caulk flange nut.CAUTION:
Press-fit bearing to such an extent that spacer is not
compressed.
2. Bevel pinion shaft
NOTE:
 If rotation torque of bevel pinion shaft exceeds specifi-
cation given below, replace pinion shaft spacer and
tighten flange nut.
 Before taking measurement of rotation torque, rotate
pinion shaft over ten rounds in advance.
1. Power wrench
3. Torque wrench

7D-16 TRANSFER
RIGHT CASE
1) Press-fit intermediate right bearing to intermediate shaft.
2) Install intermediate center oil seals (1) to case by using spe-
cial tool and apply grease to oil seal lip.
Special tool
(A) : 09924-84510-005
(B) : 09913-75821
“A” : Grease 99000-25010
Transfer intermediate center oil seals installing depth
“a” : 16.0 – 16.5 mm (0.630 – 0.650 in.)
“b” : 4.0 – 4.5 mm (0.157 – 0.177 in.)
3) Install intermediate shaft to right case, and install snap ring.
Special tool
(A) : 09952-76011
4) Install right case oil seal (1) to right case (2).
Special tool
(A) : 09913-75810
Transfer right case oil seal installing depth
“a” : 1.0 – 1.5 mm (0.039 – 0.059 in.)
5) Fill grease to inside of oil seal about 3 g (0.11 oz), and apply
grease to oil seal lip.
“A” : Grease 99000-25010
6) Install bevel gear shim(s) (2) selected in item BEVEL GEAR
SHIM ADJUSTMENT and driven gear bearing outer race (3)
to right case (1). CAUTION:
Use care the installation direction and depth of oil seals
for correct installation.

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

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-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

7F-6 REAR DIFFERENTIAL
DIFFERENTIAL UNIT
DISMOUNTING
1) Hoist vehicle and remove wheels.
2) Drain oil from rear differential. (Refer to “OIL CHANGE” in
this section.)
3) Remove brake drum and disconnect parking brake cable
from brake back plate.
4) Remove axle shafts, refer to “REAR AXLE SHAFT AND
WHEEL BEARING REMOVAL” in Section 3E.
5) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown.
6) Remove differential carrier bolts and differential assembly
with viscous coupling case.
1. Drain plug
2. Level plug
1

REAR DIFFERENTIAL 7F-7
REMOUNTING
Reverse removal procedure for installation, noting the following.
Rear Differential
Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 9900-31110
Install differential carrier assembly to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Install propeller shaft to joint flange aligning match marks (2)
and tighten propeller shaft bolts to specified torque.
Tightening torque
Propeller shaft bolts
(b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Rear Axle Shaft
For installation of rear axle shaft, refer to “REAR AXLE SHAFT
AND WHEEL BEARING INSTALLATION” in Section 3E.
Rear Brake Drum
For installation of rear brake drum, refer to “BRAKE DRUM
INSTALLATION” in Section 5.
Differential Gear Oil
Refill differential housing with new specified oil. Refer to “OIL
CHANGE” in this section for refill.
Brake Circuit Air Purging
Make sure to purge air out of brake circuit. Refer to “BLEEDING
BRAKES” in Section 5.
Then check to ensure that joint seam of pipe is free from oil leak.
UNIT DISASSEMBLY
Remove bolts (1) and separate viscous coupling case from differ-
ential carrier.1

7F-10 REAR DIFFERENTIAL
REAR DIFFERENTIAL
DISASSEMBLY
1) Put identification marks (4) on differential side bearing caps
(3) and differential carrier (1).
2) Take off differential side bearing caps by removing their bolts
and remove differential gear assembly (2).
3) With aluminum plates placed on vise first, grip differential
case with it and remove drive bevel gear by removing its
bolts.
4) Using special tools, pull out differential side bearings.
Special tool
(A) : 09913-60910
(B) : 09925-88210
5) Remove differential pinion shaft.
6) Remove differential side gear, pinions and washers.
7) Uncaulk bevel pinion nut.
8) Hold differential input hub with special tool and then remove
bevel pinion nut.
Special tool
(A) : 09927-28010
9) Remove differential input hub.
NOTE:
Check number of shims and thickness of each shim in
advance.
(A)