2005 SUZUKI JIMNY Service Workshop Manual

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3) Remove upper mounting bolt (2).
4) Remove lower mounting bolt (3).
5) Remove shock absorber (1).
INSTALLATION
1) Install shock absorber (1), refer to figure for proper installing
direction of bush and washer (2).
Tighten bolts (3) temporarily by hand.
2) Remove floor jack.
3) Lower hoist.
4) Tighten shock absorber bolts (3) to specified torque.
Tightening torque
Shock absorber upper and lower bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Support rear axle housing (1) by using floor jack (2).
3) Remove brake flexible hose E-ring (2).
NOTE:
Tighten lower bolt with vehicle off hoist and in non-
loaded condition.
1. Brake flexible hose

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4) Remove shock absorber lower mounting bolt (2).
5) Lower rear axle housing (2) gradually as far down as where
coil spring (1) can be removed.
6) Remove coil spring (1).
7) Remove spring rubber seat (1).
1. Shock absorber

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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.

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Bump Stopper
REMOVAL
1) Hoist vehicle.
2) Remove wheel.
3) Remove bump stopper (1) by using special tool.
Special tool
(A) : 09941-66010
INSTALLATION
1) Tighten bump stopper (1) to specified torque by using spe-
cial tool.
Special tool
(A) : 09941-66010
Tightening torque
Bump stopper
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
2) 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)
3) Lower hoist.
Lateral Rod
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod mounting bolt (2) and nut (3).
3) Remove lateral rod (1).

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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).

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7) Remove bushings (1) by using hydraulic press and special
tools.
Special tool
(A) : 09924-74510
(B) : 09951-16030
(C) : 09951-26010
INSTALLATION
1) Install bushings (1) by using hydraulic press and special
tools, noting the following points.
Special tool
(A) : 09913-85210
(B) : 09951-26010
For axle side bushings (1), install them so that center line
and slit lines of them are parallel as shown figure.
2. Slit
3. Center line of bushings
4. Slit line of bushings

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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.

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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.