2005 SUZUKI JIMNY bolts

Downloaded from www.Manualslib.com manuals search engine 3D-30 FRONT SUSPENSION
INSTALLATION
1) Set knuckle seal cover (2), knuckle seal (4) and knuckle seal
retainer (5) on front axle housing (6).
2) Apply grease within the knuckle (1). Amount of grease to be
applied within the knuckle (1) is approximately 100 g (for
4WD).
“A” : Grease 99000-25030
3) Apply grease to kingpin bearings (3) and install them to front
axle housing (6).
“A” : Grease 99000-25030
4) Apply sealant to indicated part of kingpin (1).
“A” : Sealant 99000-31090
5) Install steering knuckle (1) and king pins (2) and tighten king-
pin bolts to specified torque.
Tightening torque
Kingpin bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
6) Apply grease to all around of knuckle seal lip.
“A” : Grease 99000-25010
7) Install knuckle seal retainer (1), knuckle seal (2) and knuckle
seal cover (3), tighten bolts to specified torque.
Tightening torque
Knuckle seal cover bolts
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) NOTE:
When reusing bearing (3), install bearing (3) with sealing
at the top.
NOTE:
Install knuckle seal cover (3) and knuckle seal retainer (1)
so that their split section comes at the top as shown in
figure.
4. Steering knuckle 5. Split part

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-31
8) Press-fit spindle bushing (2) to wheel spindle (1) by using
special tool.
Set cut part (4) of spindle bushing (2) as shown in figure
(opposite side of the groove (3) of wheel spindle).
Special tool
(A) : 09922-55131
9) Press-fit spindle oil seal (1) until it becomes flush with wheel
spindle (2) surface by using special tool, and then apply
grease to its lip.
Special tool
(A) : 09944-66020
10) Apply grease to spindle oil seal lip.
“A” : Grease 99000-25010
11) Apply grease to spindle bushing inside surface and flange
(2).
“A” : Grease 99000-25010
12) Install wheel spindle to knuckle, coat their mating surface
with sealant.
“B” : Sealant 99000-31110 or 99000-31090
13) Install wheel spindle (1) and disc dust cover (2) to steering
knuckle. Tighten wheel spindle bolts to specified torque.
Tightening torque
Wheel spindle bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
CAUTION:
As this hole is a part of the passage of the vacuum that
activates the air locking hub, if it is clogged with grease,
the air locking hub cannot be locked or unlocked.
Therefore, be careful not to apply too much grease to
avoid clogging the vacuum passage.

Downloaded from www.Manualslib.com manuals search engine 3D-34 FRONT SUSPENSION
4) Install axle shaft (2) to front axle housing (1) (for 4WD).
5) Install knuckle to front axle housing. For details, refer to
“Steering Knuckle / Wheel Spindle” in this section.
6) Refill front axle (differential) housing with new specified gear
oil (for 4WD). Refer to “Maintenance Service” in Section 7E
for refill.
7) After servicing, check that no oil leakage exists.
Steering Knuckle Seal
REMOVAL
1) Hoist vehicle.
2) Remove knuckle seal cover bolts and seal cover (1).
3) Cut oil seal in place with scissors or knife, and take it off.
INSTALLATION
1) Cut replacement oil seal at one place with scissors or a
knife.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-35
2) Apply grease to oil seal lip.
“A” : Grease 99000-25010
3) Install oil seal retainer (1), oil seal (2) and oil seal cover (3) to
steering knuckle (4).
Tighten bolts to specified Torque
Tightening torque
Knuckle seal cover bolts
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Lateral Rod
REMOVAL
1) Hoist vehicle.
2) Remove mounting bolts of lateral rod (1).
3) Remove lateral rod (1).
INSTALLATION
1) Install lateral rod (1) to vehicle body and front axle housing,
referring to figure for proper installing direction of bolts.
Bolt and nut should not be tightened.
2) Lower hoist and with vehicle in non-loaded condition, tighten
bolt and nut of lateral rod to specified torque.
Tightening torque
Lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft) NOTE:
Install the seal (2) in oil seal retainer (1), bringing the split
part (5) to top side and locating it about 30° off the
matching face of oil seal retainer (1).
NOTE:
For left hand steering vehicle, install lateral rod with its
bending point (2) placed to right side of vehicle.
[A] : Right hand steering vehicle
[B] : Left hand steering vehicle

Downloaded from www.Manualslib.com manuals search engine 3D-36 FRONT SUSPENSION
Leading Arm / Bushing
REMOVAL
1) Hoist vehicle.
2) Remove air locking hub vacuum pipe clamp bolts (2) (for
4WD).
3) Support front axle housing by using floor jack.
4) Remove shock absorber lower mounting bolt, refer to “Front
Shock Absorber” in this section.
5) Remove mounting bolts and leading arm (1).
6) Remove bushings by using hydraulic press and special
tools.
Special tool
(A) : 09924-74510
(B) : 09951-16030
(C) : 09951-26010
1. Leading arm (right side)

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-37
INSTALLATION
1) Install bushings (1) by using hydraulic press and special
tools, noting the following point.
Install bushings (1) so that either face of bushing are aligned
with housing edge of leading arm (2), also the length
between the aligned side end of bushing and leading arm (2)
are within specification below.
Special tool
(A) : 09913-85210
(B) : 09951-26010
Specification for leading 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 leading arm (1) to vehicle body and axle housing,
referring to figure for proper installing direction of bolts.
Nuts should not be tightened.
3) Install shock absorber lower mounting bolt, refer to “Front
Shock Absorber” in this section.
4) Install air locking hub vacuum pipe clamp bolts and tighten
them to specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
5) Lower hoist and with vehicle in non-loaded condition, tighten
nuts of leading arm to specified torque.
Tightening torque
Leading arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
2. Vacuum hose
3. Body outside
[A] : Front
[B] : Rear

Downloaded from www.Manualslib.com manuals search engine 3D-38 FRONT SUSPENSION
Front Axle Housing
REMOVAL
1) Hoist vehicle.
2) Remove front wheels.
3) Drain front differential gear oil (for 4WD).
4) Remove caliper carrier bolts (R&L) and suspend caliper.
5) Remove right and left brake disc.
6) Remove wheel speed sensor (if equipped with ABS).
7) Disconnect spindle vacuum hoses from wheel spindle (for
4WD).
8) Remove tie rod (and drag rod) end nuts and disconnect tie
rod (and drag rod) ends (2) from knuckle arm (1) (R&L) with
special tool.
Special tool
(A) : 09913-65210 CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
NOTE:
If brake disc can not be removed by hand, use 8mm bolts
(1).
CAUTION:
Give match mark to spindle vacuum hose and wheel
spindle before removal.
1. Vacuum hose to lock
2. Vacuum hose to unlock

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-39
9) Remove knuckle seal cover bolts, take off knuckle seal cover
(1), knuckle seal and knuckle seal retainer.
10) Remove upper and lower kingpins (2) from steering knuckle.
11) Remove knuckle with hub assembly from axle housing (for
2WD model) or draw out right and left axle shafts with
knuckle and hub assembly (for 4WD model).
12) Before removing front propeller shaft (1), give match marks
(3) on joint flange (2) and front propeller shaft as shown (for
4WD).
13) Remove front differential from front axle housing (for 4WD).
14) Remove air locking hub vacuum pipe from axle housing (1)
(for 4WD).
15) Support front axle housing by using floor jack.
16) Remove lateral rod, refer to “Lateral Rod” in this section.
17) Remove stabilizer bar, refer to “Stabilizer Bar / Bushings” in
this section.
18) Loosen mounting nuts of leading arm (1) but don’t remove
bolts. NOTE:
The removed upper and lower kingpins (2) must be kept
separated so as to prevent an error when putting them
back in their place in reassembly.
NOTE:
At this time, lower kingpin bearing sometimes falls off.
So remove bearing while pulling off knuckle gradually.