[gregdixon]

I have just pulled the right hand side front diff seal out and thought i would post some pictures of the steps. It os only a guide to give an idea of what you are up against when attempting this. I am still waiting for the seal so if anyone is interested i can post some pictures of me putting it back in.

Start by draining the oil and removing the tyre, brake caliper (don't forget to unclip brake line from Strut) and steering arm. The disc should be free place it some where safe.




Next step remove the end of the hub and take off the circlip and washer.



Place a jack under the wishbone so the spring doesn't fall out. Undo the strut brace and the three nuts holding the top of the strut.


this is the fun bit remove the strut and hub assembly. To free the hub from the ball joint i gave the hub assembly a few taps but if you have a ball joint remover i would reccomend using it.




once the strut/hub are removed it is time to pull out the drive shaft. The manual said to use a tyre lever but a large screw driver does the job. pry out the shaft off the snap ring holding it. I found mine to be quite difficult to pull out and subsequently damaged the thrust washer on the cv.




I measured the depth of the seal in the diff housing just to be safe. mine was 3mm but be sure to check your own.


This is everything out.




i hope this is helps. It took about an hour to do but if you have the time to spare take it. In the end i think it was just sand in the seal causing it to leak.

[Stuey]

Good on you for taking the time to post this up. I'm sure it will help someone out when they take on a similar project. I'm about to do a whole housing/diff swap on my Vit, but mine is an earlier model. Very similar process though. I'll be making sure to change all the seals for new ones just to be sure as the donor housing is second hand and I don't know the history of it. Better safe than sorry. From the pics it looks like yours was spewing out a bit of oil.

[ZX1990]

Just a tip - make sure you order the hub ring as well - its a nylon bush which slides into the diff, and sits behind the new seal, which supports the CV to stop the movement which becomes present as the Diff wears. Quite often the leak is caused by this movement rather than the actual seal wearing out.... In my case, a new seal didn't stop the leak, but once I fitted this bush more recently - it has cured it completely

The Suzuki Part number is: 27619-65D00 - was $104.40 when I bought one a few months ago.

Cheers

James

[gregdixon]

thanks for that James.
I shall look into it.