2005 SUZUKI JIMNY ect

Downloaded from www.Manualslib.com manuals search engine 3E-8 REAR SUSPENSION
INSTALLATION
1) Install spring rubber seat (1).
2) Install coil spring (2) on spring seat (1) of axle housing and
then raise axle housing.
3) Install shock absorber lower mounting bolt.
Tighten bolt temporarily by hand.
4) Install brake flexible hose E-ring.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
6) Lower hoist and tighten absorber lower bolt (2) to specified
torque.
Tightening torque
Shock absorber lower bolt
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft) NOTE:
Before installing spring rubber seat (1), apply soap water
on it.
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.)
NOTE:
For tightening of lower bolt (2), refer to NOTE given under
“Shock Absorber” in this section.

Downloaded from www.Manualslib.com manuals search engine 3E-10 REAR SUSPENSION
INSTALLATION
1) Install lateral rod to vehicle body and rear axle housing.
Tighten bolt and nut temporarily by hand.
2) Lower hoist and with vehicle in non-loaded condition, tighten
lateral rod bolt and nut to specified torque.
Tightening torque
Lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Trailing Arm / Bushing
REMOVAL
1) Hoist vehicle.
2) Support rear axle housing (1) by using floor jack (2).
3) Disconnect parking brake cable clamp (1) from trailing arm.
4) Disconnect wheel speed sensor harness clamps (2) from
trailing arm (if equipped with ABS).
5) Remove trailing arm mounting bolts.
6) Remove trailing arm (1).

Downloaded from www.Manualslib.com manuals search engine 3E-12 REAR SUSPENSION
Install bushings so that either face of bushing are aligned
with housing edge of leading arm, also the length between
the aligned side end of bushing and trailing arm (1) are
within specification below.
Specification for trailing arm bushing protrusion
“a” : 8.5 – 10.5 mm (0.33 – 0.41 in.)
“b” : 6.0 – 9.0 mm (0.24 – 0.35 in.)
2) Install trailing arm (1) to vehicle body and rear axle housing,
referring to figure for proper installing direction of bolts.
3) Remove floor jack.
4) Connect wheel speed sensor harness clamps to trailing arm
(if equipped with ABS).
5) Connect parking brake cable clamp to trailing arm.
6) Lower hoist and with vehicle in non-loaded condition, tighten
trailing arm nuts to specified torque.
Tightening torque
Trailing arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove rear brake drum and disconnect parking brake
cable from brake back plate. For details, refer to “Brake back
plate” in Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug.

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-13
4) Remove wheel speed sensor (4) from rear axle housing (if
equipped with ABS).
5) Disconnect brake pipe(s) (2) from wheel cylinder and put
wheel cylinder bleeder plug cap (1) onto pipe to prevent fluid
from spilling.
6) Remove brake back plate nuts (3) from axle housing.
7) Using special tools indicated, draw out axle shaft with brake
back plate.
Special tool
(A) : 09942-15510
(B) : 09943-35511 or 09943-35512
8) If equipped with ABS, in order to remove sensor rotor from
retainer ring, grind with a grinder one part of the sensor rotor
as illustrated till it becomes thin.
9) Break with a chisel the thin ground sensor rotor, and it can
be removed (if equipped with ABS). CAUTION:
Do not pull wire harness or twist more than necessary
when removing rear wheel speed sensor (4).
Do not cause damage to surface of rear wheel speed
sensor (4) or pole piece and do not allow dust, etc. to
enter its installation hole.

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 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).