2006 SUZUKI SX4 boot

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-2
Diagnostic Information and Procedures
Front Drive Shaft Symptom DiagnosisS6RW0D3114001
Repair Instructions
Front Drive Shaft ComponentsS6RW0D3116001
Condition Possible cause Correction / Reference Item
Abnormal noiseWorn or breakage of the drive shaft jointReplace.
Worn or breakage of the center bearingReplace.
1
9A
1112
10
9A
13
3
2
1
1
14
4
5
6
5
4
7
8
15
[A]
3
4
5
6
5
4
7
16
1
17
18
15
[B]
I6RW0D311002-01
[A]: M/T model 10. Center bearing support circlip
[B]: A/T model 11. Center bearing support
1. Circlip12. Center bearing
2. Differential side joint (Constant velocity DOJ)
: Apply dark gray grease included in spare part to joint.13. Center shaft
3. Snap ring 14. Cage
4. Boot band (Large) 15. Damper (if equipped)
5. Boot 16. Differential side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
6. Boot band (Small) 17. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
7. Wheel side joint (Constant velocity ball joint)
: Apply black grease included in spare part to joint.18. Tripod joint spider
: Never disassemble.
8. Center shaft side joint (Constant velocity DOJ)
: Apply dark gray grease included in spare part to joint.: Do not reuse.
9. Oil seal
: Apply grease to oil seal lip.

Downloaded from www.Manualslib.com manuals search engine 3A-3 Drive Shaft / Axle: Front
Front Drive Shaft Assembly On-Vehicle
Inspection
S6RW0D3116002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for
smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S6RW0D3116003
Removal
1) Hoist vehicle and remove front wheel.
2) Undo caulking and remove drive shaft nut (1) with
brake pedal depressed.
3) Drain transaxle oil and transfer oil (4WD model).
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).5) Remove brake hose mounting bolt (1) and brake
hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
6) Remove suspension control arm ball joint bolt (4)
from knuckle.
7) Disconnect front suspension control arm ball joint
stud from steering knuckle.
8) Using tire lever (1) or plastic hammer (3), pull out
drive shaft joint (2) so as to release snap ring fitting
of joint spline at differential side, at center shaft or at
transfer side.
I6RW0B310005-01
I3RM0A310003-01
[A]: Left side shaft
[B]: Right side shaft of 2WD vehicle
[C]: Right side shaft of 4WD vehicle
I6RW0D311003-01
I5RW0A311003-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-4
9) Remove drive shaft assembly.
10) Remove center bearing support bolts (3) and remove
center bearing support (2) with center shaft (1) from
differential side gear, if equipped.
Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.
• Make sure that differential side joint is
inserted fully and its snap ring is seated as
it was.

Install drive shaft assembly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque
referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as specified referring to “Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A” and “Transfer Oil Change in
Section 3C” (4WD model).
• Check toe setting referring to “Front Wheel Alignment
Inspection and Adjustment in Section 2B” and adjust
as required.
Front Drive Shaft Disassembly and ReassemblyS6RW0D3116004
Disassembly
For DOJ type
CAUTION!
Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint [A]:
Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint [B]:
Draw hooks of boot big band together and remove
band.3
2
1I2RH01310007-01
I4RH0A310004-01

Downloaded from www.Manualslib.com manuals search engine 3A-5 Drive Shaft / Axle: Front
2) Remove differential side (or center shaft side) boot
small band (1) using flat end rod (2) or the like.
3) Slide boot (1) toward the center of shaft and remove
snap ring (2) from outer race, and then take shaft out
of outer race (3).
4) Wipe off grease and remove circlip (1) used to fix
cage (2) by using snap ring pliers (3).5) Draw away cage (1) by using bearing puller (2), and
remove boot (3) from shaft.
6) Pull out differential side (or center shaft side) boot
and damper from shaft.
7) Undo caulking (5) of wheel side boot big band (1)
and small band (3) using flat end rod (2) or the like,
then pull out wheel side boot (4) from shaft.
2
1
I5RS0B310005-01
I2RH01310012-01
I5RS0B310006-01
I2RH01310014-01
I4RS0A310006-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-6
For tripod joint type
CAUTION!
• Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.
• Do not disassemble tripod joint spider. If
any malcondition is found in it, replace it
as differential side joint assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint:
Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint:
Draw hooks of boot big band together and remove
band.2) Wipe off grease from shaft and take off snap ring (1)
using snap ring pliers (2).
3) Remove tripod joint spider (1) using 3 arms puller
(2).
CAUTION!
To prevent any problem caused by washing
solution, do not wash tripod joint except its
housing. Degreasing of tripod joint with cloth
is allowed.

4) Remove differential side (or center shaft side) boot
small band, and then pull out differential side (or
center shaft side) boot from shaft.
5) Remove damper from shaft, if equipped.
6) Undo caulking (5) of wheel side boot big band (1)
and small band (3) using flat end rod (2) or the like,
then pull out wheel side boot (4) from shaft.
[A]: For boot big band without joint
[B]: For boot big band with joint
I4RH0A310004-01
I7RW01311003-01
I3RH0A311004-01
I4RS0A310006-01

Downloaded from www.Manualslib.com manuals search engine 3A-7 Drive Shaft / Axle: Front
Reassembly
For DOJ type
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly and DOJ
housing are washed thoroughly and air dried.
Replace boot(s) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as
gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• To ensure full performance of joint as
designed, be sure to distinguish between
two types of grease in repair set and apply
specified volume to respective joint
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After
washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Fit boot (1) to grooves of shaft and housing (2).
7) Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
8) Place new wheel side boot big band (3) and small
band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.9) Fasten boot bands (1) using special tool as shown in
figure.
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(A): 09943–57010
21I5RS0B310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-8
10) Install damper (1) to specified position on drive shaft.
Drive shaft damper installing position
“a”: 354 mm (13.9 in.) (right side)
“a”: 252 mm (9.9 in.) (left side)
11) Set new differential side (or center shaft side) small
band and new differential side (or center shaft side)
boot on shaft temporarily.
12) Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
13) Install circlip (1) by using snap ring pliers (2).14) Apply grease to entire surface of cage. Use specified
grease in tube included in spare parts.
15) Insert cage into joint housing (2) and fit snap ring (1)
into groove of joint housing (2).
CAUTION!
Position opening of snap ring “c” so that it
will not be lined up with a ball.

16) Apply grease (including in spare parts) to inside of
joint housing (1).
Grease color
“A”: Dark gray
Amount
“A”: 75 – 95 g (2.6 – 3.4 oz) (right side)
“A”: 70 – 90 g (2.5 – 3.2 oz) (left side)
I5RW0A311004-01
(A)
1
I5RS0B310009-01
I5RS0B310010-01
I2RH01310036-01
I5RS0B310011-02

Downloaded from www.Manualslib.com manuals search engine 3A-9 Drive Shaft / Axle: Front
17) Fit boot (1) to grooves of shaft and housing (2) and
adjust length to specification below.
Insert screw driver into boot and allow air to enter
boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between housing end and small boot band
center)
Left side drive shaft “a”: 170 mm (6.69 in.)
Right side drive shaft “b”: 189 mm (7.44 in.)
CAUTION!
• Bend each boot band against forward
rotation.
• Do not squeeze or distort boot when
fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

18) Place differential side boot (or center shaft side) new
big band (3) and new small band (4) onto boot
putting band outer end (1) against forward rotation
(2) as shown in figure.19) Fasten differential side (or center shaft side) boot
band.
• For differential side (or center shaft side) boot big
band
Fasten band (1) by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
• For differential side (or center shaft side) boot
small band
Fasten band (5) using special tool as shown in
figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(B): 09943–57010
[A]: Left side drive shaft
[B]: Right side drive shaft
I5RW0A311005-01
I5JB0A311006-01
(A)
1
4
2
3
(B)
5“a”
I5RS0B310013-01