Repairing the differential gear on a Suzuki Alto—or any vehicle, for that matter—requires a good understanding of the vehicle’s drivetrain, tools, and safety procedures. click here for more details on the download manual…..

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Suzuki Alto / Nissan Pixo Gearbox Removal Repair and Replacement How to remove and replace a gearbox on a Seventh generation Suzuki Alto or Nissan Pixo. This particular car is a 2014 car with …

Here’s a detailed guide on how to perform differential gear repair on a Suzuki Alto.

### Tools and Equipment Needed:
1. **Basic Hand Tools**:
– Socket set (including extensions)
– Wrenches (metric sizes)
– Screwdrivers (flathead and Phillips)
– Pliers
– Hammer
– Torque wrench

2. **Specialized Tools**:
– Gear puller
– Differential case spreader
– Dial indicator (for measuring backlash)
– Bearing press
– Micrometer (for measuring gear thickness)

3. **Safety Equipment**:
– Safety goggles
– Gloves
– Mechanic’s creeper or mat

4. **Parts**:
– Replacement differential gears and bearings
– Gasket or sealant for the differential cover
– Differential oil (gear oil)
– Any other specific seals, washers, or clips as required

### Step-by-Step Repair Process:

#### 1. **Preparation and Safety**:
– **Park the Vehicle**: Ensure the vehicle is on a flat surface. Engage the parking brake.
– **Disconnect the Battery**: To prevent any electrical issues, disconnect the negative terminal of the battery.

#### 2. **Lifting the Vehicle**:
– Use a hydraulic jack to lift the rear of the Suzuki Alto and secure it on jack stands. make sure the vehicle is stable and will not move.

#### 3. **Removing the Differential Cover**:
– **Drain the Differential Fluid**: Place a drain pan under the differential and remove the drain plug or the cover bolts to let the fluid drain out completely.
– **Remove the Differential Cover**: Use a socket wrench to remove the bolts holding the differential cover. Gently tap the cover with a hammer if it’s stuck, then remove it to expose the gears inside.

#### 4. **Inspecting the Differential**:
– **Visual Inspection**: Check for any visible damage to the gears, bearings, and housing. Look for signs of wear, pitting, or cracking.
– **Check the Bearings**: Spin the differential gears and check for smooth operation. If there’s any grinding or play, the bearings may need replacement.

#### 5. **Removing the Differential Assembly**:
– **Remove Axle Shafts**: If necessary, detach the axle shafts. This usually involves removing the retaining clips and gently pulling the shafts out of the differential.
– **Remove the Differential Unit**: Use a differential case spreader to carefully separate the differential from the housing. Take note of the arrangement of shims and spacers, as they will need to be replaced in the same order.

#### 6. **Replacing Gears and Bearings**:
– **Remove Old Gears and Bearings**: Use a gear puller to extract the gears and bearings from the differential. Be careful not to damage the housing.
– **Install New Bearings**: Use a bearing press to install new bearings onto the differential gears. Ensure they are seated correctly and lubricated with gear oil.
– **Install New Gears**: Place the new differential gears into the housing, ensuring they mesh correctly with the ring gear.

#### 7. **Reassembling the Differential**:
– **Install Shims**: Reinsert the shims and spacers in the same order as they were removed. This is crucial for maintaining proper gear mesh and backlash.
– **Adjusting Backlash**: Use a dial indicator to measure the backlash between the ring and pinion gears. Adjust the shims as necessary to achieve the manufacturer’s specifications.
– **Reinstall the Differential Unit**: Carefully place the differential assembly back into the housing.

#### 8. **Reinstalling the Differential Cover**:
– **Clean the Surface**: Ensure the mating surface of the differential housing is clean and free of old gasket material.
– **Apply Gasket Maker**: If no gasket is used, apply a bead of gasket maker evenly around the edge of the differential cover.
– **Reattach the Cover**: Secure the differential cover with bolts, tightening them in a criss-cross pattern to ensure an even seal.

#### 9. **Refilling Differential Fluid**:
– **Add New Differential Oil**: Reinstall the drain plug if removed and fill the differential with new gear oil through the fill hole until it reaches the specified level.

#### 10. **Final Checks**:
– **Reinstall Axle Shafts**: If removed, reinsert the axle shafts and secure them with retaining clips.
– **Check for Leaks**: Start the vehicle and let it run for a few minutes while checking for leaks around the differential and axle seals.

#### 11. **Lowering the Vehicle**:
– Remove the jack stands and lower the vehicle back to the ground. Reconnect the battery.

### Conclusion:
This repair process requires mechanical knowledge and skills, as well as patience and attention to detail. If you are not comfortable performing this repair, it is advisable to seek assistance from a qualified mechanic. Always refer to the Suzuki Alto service manual for specific torque specifications and procedures.
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