2000 SUZUKI SWIFT RG413 Service Workshop Manual

4A-12 FRONT DRIVE SHAFT
7) Driver in the cage (1) by using a pipe (2).
Drive shaft joint cage installing pipe diameter
“a” : 22.5 mm (0.886 in.) or more
“b” : 30.0 mm (1.181 in.) or less
8) Install circlip (1) by using special tool (A).
Special tool
(A) : 09900-06107
9) Apply grease to entire surface of cage.
Use specified grease in tube included in spare parts.
10) Insert cage into outer race and fit snap ring (1) into groove of
outer race (2).
11) Apply grease to inside of outer race, and fit boot to outer
race. After fitting boot, insert screwdriver into boot on outer
race side and allow air to enter boot so that air pressure in
boot becomes the same as atmospheric pressure. CAUTION:
Install cage directing smaller outside diameter side to
wheel side.
CAUTION:
Position opening of snap ring “c” so that it will not be
lined up with a ball.

FRONT DRIVE SHAFT 4A-13
12) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measurements become as indicated
below.
Drive shaft boot fixing position
“d” : 157.8 mm (6.21 in.) for left side
“e” : 192.9 mm (7.59 in.) foe right side
For Center Shaft and Center Bearing Support
Install center shaft by reversing removal procedure and noting fol-
lowing points
When installing bearing support circlip (1), make sure that if
fits in circlip groove in center bearing support (2) securely as
shown.
When installing left oil seal (1), use care so that oil seal in
proper direction as shown figure.
Be sure to apply grease to oil seal lip and bearing side space
indicated in figure.
“A” : Grease 99000-25010
After press-fit center shaft (2) from left oil seal side, install
circlip to groove of center shaft securely. CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with
cloth is allowed.
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.
[A] : Differential side

4A-14 FRONT DRIVE SHAFT
When installing right oil seal (1), use care so that oil seal in
proper direction as shown figure.
Be sure apply grease to oil seal lip and bearing side space
indicated in figure.
“A” : Grease 99000-25010
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.
Clean front wheel bearing oil seal (1) and then apply grease.
Replace it if required.
“A” : Grease 99000-25010
CAUTION:
To avoid excessive expansion of boot and consequen-
tial disconnection of joint in boot, do not pull differen-
tial side joint housing.
Protect oil seals and boots from any damage, prevent-
ing them from unnecessary contact while installing
drive shaft.
Do not hit joint boot with hammer. Inserting joint only
by hands is allowed.
Make sure that differential side joint is inserted fully
and its snap ring is seated as it was.

FRONT DRIVE SHAFT 4A-15
Tighten each bolt and nut to the specified torque.
Tightening torque
Transfer oil filler/level and drain plugs (a) :
21 N·m (2.1 kg-m, 15.5 lb-ft)
Transmission oil filler/level and drain plugs (b) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
Ball stud bolt (c) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Tie rod end castle nut (d) :
35 - 50 N·m (3.5 - 5.0 kg-m, 25.5 - 36.0 lb-ft)
Drive shaft nut (e) : 175 N·m (17.5 kg-m, 127.0 lb-ft)
Wheel nut (f) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Center bearing support bolts (g) :
50 N·m (5.0 kg-m, 36.0 lb-ft)
Apply sealant to drain plug (1) and filler/level plug (2) for
manual transmission.
“A” : Sealant 99000-31110
Apply sealant to drain plug (9) and filler/level plug (10) for
transfer. (For 4WD model)
“A” : Sealant 99000-31110
Fill transmission or transfer with oil as specified. (Refer to
Section 7A, 7B or 7D.)
[A] : For M/T vehicle
[B] : For A/T vehicle
[C] : For 4WD model
[D] : For vehicle equipped with center shaft
3. Drain plug (for A/T vehicle)
4. Ball stud bolt
5. Castle nut
6. Drive shaft nut
7. Wheel nut
8. Center bearing support bolt

4A-16 FRONT DRIVE SHAFT
TIGHTENING TORQUE SPECIFICATION
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
Fastening portionTightening torque
Nm kg-m lb-ft
Transfer oil filler/level and drain plugs 21 2.1 15.5
Transmission oil filler/level and drain plugs 23 2.3 17.0
Ball stud bolt 60 6.0 43.5
Tie rod end castle nut 35 - 50 3.5 - 5.0 25.5 - 36.0
Drive shaft nut 175 17.5 127.0
Wheel nut 85 8.5 61.5
Center bearing support bolts 50 5.0 36.0
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lips
Sealant SUZUKI BOND NO. 1215
(99000-31110)Oil drain and filler plug for manual
transmission or transfer
09913-65210 09900-06107 09900-06108
Tie-rod end remover Snap ring pliers (Open
type)Snap ring pliers (Closing
type)

PROPELLER SHAFTS 4B-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
4B
8D
8E
9
10
10A
10B
SECTION 4B
PROPELLER SHAFTS
CONTENTS
GENERAL DESCRIPTION .............................. 4B-1
DIAGNOSIS ..................................................... 4B-1
DIAGNOSIS TABLE ..................................... 4B-1PROPELLER SHAFT JOINT CHECK.......... 4B-2
ON-VEHICLE SERVICE .................................. 4B-2
TIGHTENING TORQUE SPECIFICATION...... 4B-4

GENERAL DESCRIPTION
Most universal and constant velocity joints require no maintenance. They are lubricated for life and can not be
lubricated on the vehicle. If universal and constant velocity joints becomes noisy or worn, it must be replace.
The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained.
DIAGNOSIS
DIAGNOSIS TABLE
Condition Possible Cause Correction
Abnormal noise
Loose universal joint bolt Tighten universal joint bolt.
Spider bearing worn out or stuck Replace.
Wear spider Replace propeller shaft.
Vibration
Performed propeller shaft Replace.

4B-2 PROPELLER SHAFTS
PROPELLER SHAFT JOINT CHECK
If universal joints are suspected of producing chattering or rattling
noise, inspect them for wear. Check to see if cross spider rattles
in yokes or if splines are worn down and replace defective propel-
ler shaft with new one.
Noise coming from universal joint can be easily distinguished
from other noises because rhythm of chattering or rattling is in
step with cruising speed. Noise is pronounced particularly on
standing start or in coasting condition (when braking effect of
engine is showing in the drive line).
ON-VEHICLE SERVICE
REMOVAL
1) Hoist vehicle.
2) Before removing propeller shaft, give match mark (1) on pro-
peller shaft and companion flange as shown. Also give
match mark (1) on propeller shaft No.2 and center support
flange of propeller shaft No.1.
3) Loosen propeller shaft bolt at front and rear end, and sepa-
rate propeller shaft from transfer and rear differential.
1. Propeller shaft No.1
2. Center support
3. Propeller shaft No.2
4. Forward
Tightening torque

PROPELLER SHAFTS 4B-3
4) Loosen propeller shaft bolt connecting propeller shaft No.1
with propeller shaft No.2, but keeping their connection provi-
sionally.
5) Loosen center support bolt, then remove propeller shaft
No.1 with No.2.
6) Disconnect propeller shaft No.1 from propeller shaft No.2.
INSPECTION
Check propeller shaft connecting bolts for looseness. If
looseness is found, tighten to specified torque.
Check propeller shaft joints for wear, rattle and damage. If
any defect is found, replace.
Check propeller shaft center support for biting of foreign mat-
ter, crack, abnormal noise and damage. If any defect is
found, replace.
Inspect propeller shaft and flange yoke for damage, and pro-
peller shaft for runout.
If damage is found or shaft runout exceeds its limit, replace.
Propeller shaft runout
Limit : 0.7 mm (0.028 in.) CAUTION:
Don’t damage joint seal (1) to prevent lubrication defect
of joint.
1. Center support
1