2005 SUZUKI JIMNY oil

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-15
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
1) Aligning serrations between new stud bolt(s) (1) and flange,
install new stud bolt(s) (1) by tightening nut (2) as shown.
2) Press-fit wheel bearing (1) and retainer ring (2) as shown.
3) For vehicle with ABS, press-fit new sensor rotor as shown.
4) Inspect axle shaft length.
Rear axle shaft length
“a” : 775.5 mm (30.5 in.) (left side),
559.5 mm (22.0 in.) (right side)
5) Apply grease to axle shaft oil seal lip (1) as shown.
“A” : Grease 99000-25010
6) Apply sealant to mating surface of axle housing (2) with
brake back plate.
“B” : Sealant 99000-31110
3. Washer
4. Flange of axle shaft
NOTE:
Use care not to cause any damage to outside of
retainer ring (2).
Refer to figure so that wheel bearing (1) is installed in
proper direction.
NOTE:
Use care not to cause any damage to outside of retainer
ring (2).
[A]: Vehicle without ABS
[B]: Vehicle with ABS
NOTE:
Make sure to remove old sealant before applying it anew.

Downloaded from www.Manualslib.com manuals search engine 3E-16 REAR SUSPENSION
7) Install rear axle shaft to rear axle housing (2) and tighten
brake back plate nuts (4) to specified torque.
Tightening torque
Brake back plate nuts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Connect brake pipe (3) to wheel cylinder and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening torque
Wheel speed sensor bolt
(c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
10) Install parking brake cable (3) to brake back plate (1).
11) Install brake shoes, referring to “Brake Shoe” in Section 5.
12) Install brake drum. Refer to “Rear Brake Drum” in Section 5.
13) Refill differential housing with new specified gear oil. Refer to
“Maintenance Service” in Section 7E for refill.
14) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “Bleeding Brakes” in Section 5.)
15) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.5 lb-ft) NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing (2).
1. Wheel speed sensor
2. Cable stopper ring

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-17
16) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load over ten times so as to obtain proper
drum-to shoe clearance.
Adjust parking brake cable. (For adjustment, refer to “Parking
Brake Check and Adjustment” in Section 5.)
17) Tighten parking brake lever cover screws.
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
19) Check each installed part for oil leakage.
Rear Axle Shaft Inner Oil Seal
REMOVAL
1) Remove rear axle shaft. For details, refer to “Rear Axle Shaft
and Wheel Bearing” in this section.
2) Remove rear axle shaft inner oil seal by using special tools.
Special tool
(A) : 09942-15510
(B) : 09944-96010 (remover)
(C) : 09921-26010 (collar)
INSTALLATION
1) Using special tools drive in oil seal (1) until it contacts oil seal
protector (2) in axle housing.
Special tool
(A) : 09913-75520
“A” : Grease 99000-25010
2) For procedure hereafter, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
NOTE:
Make sure that oil seal (1) is free from inclination as it
is installed.
Refer to figure so that oil seal (1) is installed in proper
direction.
3. Differential side

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-19
10) Loosen rear mounting nuts of trailing arm (2) but don’t
remove bolt.
11) Remove shock absorber (1) lower mounting bolt.
12) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove rear mount bolts of trailing
arm.
13) Lower rear axle housing gradually.
14) Remove axle housing.
INSTALLATION
Install removed parts in reverse order of removal, noting the fol-
lowing.
1) Place rear axle housing (1) on floor jack. Then install trailing
arm (2) rear mounting bolts (right & left) in proper direction
as shown. At this time, mount nuts but don’t tighten them.
2) Install coil spring (2) (right & left) on spring seat (1) of axle
housing and raise axle housing.
3. Out side
4. Body center
NOTE:
Upper and lower diameters of coil spring (2) are differ-
ent. Bring larger diameter end at bottom and set its
open end in place on spring seat (1).
When seating coil spring (2), mate spring end with
stepped part (3) of rear axle spring seat (1) as shown.
A: Upper side (small dia.)
B: Lower side (large dia.)

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 REAR SUSPENSION 3E-23
Special Tools
09913-75520 09913-85210 09924-74510 1) 09927-18411
Universal puller
Bearing installer Oil seal installer Bearing installer handle 2) 09921-57810
Bearing remover
09941-66010 09942-15510 09943-35511 or
09943-3551209944-96010
Bearing outer race
remover
Bump stopper wrench Sliding hammer Brake drum remover 09921-26010
Bearing outer race
remover collar
09951-16030 09951-26010
Bush remover Bush remover plate

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-3
On-Vehicle Service
Propeller Shafts
REMOVAL
1) Hoist vehicle.
2) Drain transmission oil only when servicing propeller shaft
No. 1.
3) Before removing propeller shaft (2), give match marks (1) on
each joint flange (3) and propeller shaft (2) as shown.
4) Remove propeller shaft(s).
INSPECTION
Inspect propeller shaft and flange yoke for damage, and propeller
shaft for runout.
If damage is found or shaft runout exceeds its limit, replace.
Propeller shaft runout limit : 0.8 mm (0.031 in.)