2005 SUZUKI JIMNY bolt

Downloaded from www.Manualslib.com manuals search engine 3E-20 REAR SUSPENSION
3) Install lower part of shock absorber (1) to right and left sides
of axle housing and tighten bolts (2) temporarily by hand.
4) Install lateral rod (1) and install bolts in proper direction as
shown.
At this time, mount bolt and nut but don’t tighten them.
5) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 99000-31110
6) Install differential carrier assembly (3) to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Rear differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Install propeller shaft (2) to joint flange aligning match marks
(1) and tighten flange bolts to specified torque.
Tightening torque
Rear propeller shaft bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
8) Install LSPV stay to axle housing and adjust LSPV stay posi-
tion, referring to “LSPV Assembly Inspection and Adjust-
ment” in Section 5 (if equipped with LSPV).
9) Remove floor jack from axle housing.
10) Connect brake pipes and parking brake cable onto axle
housing and clamp them securely.
For clamping positions, refer to “Rear Brake Hose / Pipe”
and “Parking Brake Cable” in Section 5.

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-21
11) Connect brake flexible hose (2) to bracket on axle housing
and secure it with E-ring (1).
12) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(a) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
13) Clean mating surface of axle housing (2) (right & left) with
brake back plate and apply sealant as shown.
“B” : Sealant 99000-31090
14) Apply grease to axle shaft oil seals lip (1) (right & left) as
shown.
“A” : Grease 99000-25010
15) Install rear axle shafts, brake shoes, brake drums and
wheels. For details, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
16) Lower hoist.
17) Tighten right and left trailing arm nuts and shock absorber
lower bolts to specified torque.
Tighten lateral rod bolt and nut to specified torque.
Tightening torque
Trailing arm nuts and lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Shock absorber lower bolts
(b) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
19) Perform brake test (foot brake and parking brake). (For
brake test, see Section 5.)
20) Check each installed part for oil leakage.
NOTE:
When tightening these bolts and nuts, be sure that vehi-
cle is off hoist and in non loaded condition.
1. Shock absorber
2. Trailing arm
3. Lateral rod

Downloaded from www.Manualslib.com manuals search engine 3E-22 REAR SUSPENSION
Tightening Torque Specifications
Required Service Materials
Fastening portionTightening torque
Nm kg-m lb-ft
Shock absorber upper and lower bolt 85 8.5 61.5
Bump stopper 50 5.0 36.5
Lateral rod bolt and nut
90 9.0 65.0
Trailing arm nut (Front and Rear)
Brake back plate nut 23 2.3 17.0
Brake pipe flare nut 16 1.6 11.5
Rear differential carrier bolt 23 2.3 17.0
Rear propeller shaft bolt (Differential case side) 50 5.0 36.5
Rear propeller shaft bolt (Shaft No.3 transfer case side) 33 3.3 24.0
Wheel nut 95 9.5 69.0
Wheel speed sensor bolt and harness clamp bolt 10 1.0 7.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
SealantSUZUKI BOND NO. 1215
(99000-31110)Joint seam of differential carrier and
axle housing
Water tight sealantSEALING COMPOUND 366E
(99000-31090)To apply to mating surfaces of brake
back plate and rear axle.
Gear oilFor gear oil information, refer to “Mainte-
nance Service” in Section 7E of this manual.Differential gear
(Rear axle housing)

Downloaded from www.Manualslib.com manuals search engine WHEELS AND TIRES 3F-3
Replacement Wheels
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated
bolt holes, if lug nuts won’t stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in “How to Measure
Wheel Runout” may cause objectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may
affect wheel and bearing life, brake cooling, speedometer / odom-
eter calibration, ground clearance to the body and chassis.
How To Measure Wheel Runout
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should
be installed to the wheel balancer of the like for proper measure-
ment.Take measurements of both lateral runout (1) and radial
runout (2) at both inside and outside of the rim flange. With dial
indicator set in place securely, turn the wheel one full revolution
slowly and record every reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit
“a” : 1.20 mm (0.047 in.)
Radial runout limit
“b” : 1.20 mm (0.047 in.)
Metric Lug Nuts and Wheel Studs
All models use metric lug nuts and wheel studs.
Metric lug nuts and wheel studs size
: M12 x 1.25

Downloaded from www.Manualslib.com manuals search engine 4B-2 PROPELLER SHAFTS
General Description
Components
Diagnosis
Diagnosis Table
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).
1. Propeller shaft No.1
2. Propeller shaft No.2
3. Propeller shaft No.3
Tightening Torque
Condition Possible Cause Correction
Abnormal noise
Loose universal joint bolt.
Spider bearing worn out or stuck.
Wear spider.Tighten universal joint bolt.
Replace.
Replace propeller shaft.
Vibration
Performed propeller shaft. Replace.

Downloaded from www.Manualslib.com manuals search engine 4B-4 PROPELLER SHAFTS
INSTALLATION
Install propeller shaft(s) reversing removal procedure noting fol-
lowing points :
When installing propeller shaft, align the match marks.
Otherwise, vibration may occur during driving.
Use following specification to torque universal joint flange.
Tightening torque
Propeller shaft bolt (propeller shaft No.1, No.2 and No.3
rear differential side)
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Propeller shaft bolt (propeller shaft No.3 transfer case
side)
(b) : 33 N·m (3.3 kg-m, 24 lb-ft)
Grease splines of propeller shaft No. 2 and No. 3.
“A” : Chassis Grease 99000-25030
Match marks (1) are provided on slip-on spline connections
of propeller shaft No. 2 and No. 3. Inserting splined end into
spIined bore without regard to match marks can be a possi-
ble cause of noise or vibration of propeller shaft. Be sure to
index marks. NOTE:
If transmission oil was drained for front propeller shaft
removal, pour specified gear oil into transmission case
to specified level.

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-7
3) Insert bearing race into opposite side of shaft yoke until it is
flush with side face of shaft yoke, tapping it by a copper
hammer.
4) In the same way as Step 2) to Step 3), insert bearing races
into flange yoke.
5) Using round bar of 22 – 24 mm (0.87 in. – 0.94 in.) in diame-
ter and hammer, tap bearing races into shaft or flange yoke
until circlips can be installed in its groove on yoke bores.
6) Install 4 circlips in each groove on shaft and flange yoke
bores.
Tightening Torque Specification
Required Service Material
NOTE:
After reassembly, ensure that both shaft yoke and
flange yoke move smoothly.
Make sure that each circlip is fitted in groove securely.
Fastening portionTightening torque
Nm kg-m lb-ft
Propeller shaft bolt (propeller shaft No.1 No.2 and No.3 rear dif-
ferential side)50 5.0 36.5
Propeller shaft bolt (propeller shaft No.3 transfer case side) 33 3.3 24
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium greaseSUPER GREASE C
(99000-25030)To apply to spider bearing race and propel-
ler shaft No.2 and No.3 splines.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-5
Diagnosis Table
Condition Possible Cause Correction
Not enough braking
forceBrake oil leakage from brake lines Locate leaking point and repair.
Brake disc or pads stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact.
Brake shoes linings stained with oil or wet with
waterReplace.
Badly worn brake shoe linings Replace.
Defective wheel cylinders Repair or replace.
Malfunctioning caliper assembly Repair or replace.
Air in system Bleed system.
Maladjusted sensor spring length of LSPV Check or adjust.
Broken sensor spring of LSPV Replace.
Defective collar of LSPV Replace.
Malfunctioning ABS (Antilock brake system), if
equippedCheck system and replace as nec-
essary.
Brake pull (Brakes not
working in unison)Pad or shoe linings are wet with water or
stained with oil in some brakesReplace.
Drum-to-shoe clearance out of adjustment in
some brakes (Malfunctioning auto adjusting
mechanism)Check for inoperative auto adjusting
mechanism.
Drum is out of round in some brakes Replace.
Wheel tires are inflated unequally Inflate equally.
Malfunctioning wheel cylinders Repair or replace.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same
amount of tread should be used on
the same axle.
Restricted brake tubes or hoses Check for soft hoses and damaged
lines.
Replace with new hoses and new
double-walled steel brake tubing.
Malfunctioning caliper assembly Check for stuck or sluggish pistons
and proper lubrication of caliper
slide bush.
Loose suspension parts Caliper should slide.
Check all suspension mountings.
Loose calipers Check and torque bolts to specifica-
tions.
Noise (high pitched
squeak without brake
applied)Front lining worn out Replace brake pads.
Rear brake locked pre-
maturelyMaladjusted sensor spring length of LSPV Check or adjust.
Malfunctioning LSPV assembly Replace assembly.
Brake locked
(For vehicles
equipped with ABS)Malfunctioning ABS, if equipped Check system and replace as nec-
essary.