2005 SUZUKI JIMNY propeller shaft

Downloaded from www.Manualslib.com manuals search engine 3E-18 REAR SUSPENSION
Rear Axle Housing
REMOVAL
1) Hoist vehicle and remove wheels.
2) Remove rear axle shaft, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
3) Disconnect brake pipe (3) from flexible hose (1) and remove
E-ring (2).
4) Remove brake pipe clamps and pipes from axle housing.
5) For jobs hereafter, support rear axle housing (2) by using
floor jack (1) under axle housing (2).
6) Remove LSPV stay from axle housing (if equipped with
LSPV).
7) Before removing propeller shaft (2), give match marks (1) on
joint flange and propeller shaft (2) as shown.
Remove propeller shaft (2).
8) Remove differential carrier assembly (3).
9) Remove lateral rod (1).

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 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 PROPELLER SHAFTS 4B-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
4B
8D
8E
9
8E
9
10
10A
10B
SECTION 4B
PROPELLER SHAFTS
CONTENTS
General Description ....................................... 4B-2
Components ................................................. 4B-2
Diagnosis ........................................................ 4B-2
Diagnosis Table ........................................... 4B-2
Propeller Shaft Joint Check .......................... 4B-2
On-Vehicle Service......................................... 4B-3Propeller Shafts ........................................... 4B-3
Universal Joint ............................................. 4B-5
Tightening Torque Specification .................. 4B-7
Required Service Material ............................. 4B-7
Special Tool .................................................... 4B-8

NOTE:
All propeller shaft fasteners are an important attaching part in that it could affect the performance
of vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any propeller shaft part. Replace it with a new part, or
damage to the part may result.

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 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.)

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-5
Universal Joint
DISASSEMBLY
1) Using special tool, remove 4 circlips (1).
Special tool
(A) : 09900-06108
2) Apply penetrate lubricant between bearing race outer diame-
ter and shaft yoke bore.
3) Using a set of special tool, push spider bearing race (1) out
3 – 4 mm (0.12 – 0.16 in.) from shaft yoke side face (2).
Special tool
(B) : 09926-48010
Pushed out value of bearing race from shaft yoke side
face
“a” : 3 – 4 mm (0.12 – 0.16 in.)
4) Tapping shaft yoke (2) with a hammer, remove bearing race
(1) from shaft yoke (2) completely.
5) Take out bearing race (1) on the opposite side of shaft yoke
(2) in the same way as shown.