2005 SUZUKI JIMNY Kingpins

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-29
7) Remove lower and upper kingpins (1).
8) Remove steering knuckle (1).
9) Remove knuckle seal cover (1), knuckle seal (2) and knuckle
seal retainer (3) from front axle housing (4).
10) Remove spindle oil seal by using special tool.
Special tool
(A) : 09913-50121
11) Remove spindle bushing by using special tools.
Special tool
(A) : 09917-88210
(B) : 09916-58210 NOTE:
Upper and lower kingpins (1), when removed, must be
marked off one from the other.
NOTE:
When steering knuckle (1) is pulled, lower kingpin
bearing sometimes falls off. So remove bearing while
pulling off the knuckle gradually.
Upper and lower kingpin bearings must be also
marked off one from the other.
1. Wheel spindle

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.

Downloaded from www.Manualslib.com manuals search engine 3D-42 FRONT SUSPENSION
9) Install right and left axle shafts to axle housing (for 4WD).
Install knuckle to axle housing (for 2WD).
10) Install kingpins (2) and knuckle seal cover (1) to steering
knuckle (R&L), refer to “Steering Knuckle / Wheel Spindle” in
this section.
11) Install right and left brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
12) Connect spindle vacuum hoses to wheel spindle (for 4WD),
while aligning the match mark.
13) Install ABS wheel sensor to steering knuckle (if equipped
with ABS).
14) Install tie rod ends and drag rod end to knuckle arm (1)
(R&L). Tighten new nuts to specified torque.
Tightening torque
Tie rod end nuts and drag rod end nut (Knuckle side)
(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
15) Install wheels and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
16) Lower hoist.NOTE:
Place knuckle seal and retainer in axle housing before
installing axle shaft (knuckle), using care for installation
direction of knuckle seal.
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut, tighten Nut (M12 x 1.25) to about 20 N·m
(2.0 kg-m, 14.5 Ib-ft) and remove it. Then tighten new nut
to specified torque.