2006 SUZUKI SX4 front drive shaft assembly

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 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-10
For tripod joint 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 (1) and tripod
joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) 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) 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.7) Fasten boot bands (1) securely 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
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-12
15) Fasten differential side (or center shaft side) boot big
band (1) and small band (5) by drawing hooks (2)
with special tool and engage hooks (3) in slot and
window (4).
Special tool
(A): 09943–57021Center Shaft and Center Bearing Support
Disassembly and Reassembly (If Equipped)
S6RW0D3116005
Disassembly
1) Using hydraulic press (1), draw out center shaft (2)
from center bearing.
2) Remove oil seals from center bearing support (3).
3) Remove bearing support circlip (1) using snap ring
pliers (2).
4) Remove center bearing from center bearing support.
Reassembly
Install center shaft by reversing removal procedure and
noting the following points.
• When installing bearing support circlip (1), make sure
that if fits in circlip groove in center bearing support (2)
securely as shown.
(A)
1
4
2
3
(A)
5
4
2
3
I4RS0B310008-02
I3RM0A310012-01
I7RW01311005-01
2
1
I5RW0A311006-01

Downloaded from www.Manualslib.com manuals search engine 3A-13 Drive Shaft / Axle: Front
• When installing left oil seal (1) and right oil seal (2)
using special tool, use care so that oil seals in proper
direction and position as shown in the figure.
Special tool
: 09925–15410
Distance
“a”: 0 – 1 mm (0 – 0.04 in.)
“b”: 8 – 9 mm (0.13 – 0.35 in.)
• Be sure to apply grease to oil seal lip and bearing side
space indicated in the figure.
“A”: Grease 99000–25011 (SUZUKI Super Grease
A) • Press-fit center shaft (1) from left oil seal (2) side.
Specifications
Tightening Torque SpecificationsS6RW0D3117001
NOTE
The specified tightening torque is also described in the following.
“Front Drive Shaft Assembly Components Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
2 1
“A”
“b”
“a” “A”
I5RW0A311007-01
12
I5RW0A311008-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Brake hose mounting bolt 25 2.5 18.0)

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Rear 3A-16
Rear Drive Shaft Assembly Removal and
Installation
S6RW0D3126002
Removal
1) Hoist vehicle and remove rear wheel.
2) Undo caulking of drive shaft nut (1) and then remove
drive shaft nut with pull up parking brake lever.
3) Remove rear drive shaft flange nuts (1), and then
remove rear drive shaft.
Installation
Install drive shaft assembly by reversing removal
procedure and noting the following points.
CAUTION!
• Protect boots from any damage,
preventing them from unnecessary contact
while installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.

• Tighten each nuts to specified torque referring to
“Rear Drive Shaft Components”.
Rear Drive Shaft Disassembly and ReassemblyS6RW0D3126003
Disassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following point which is different
from the front drive shaft is described.
• Remove differential side boot big band and small
band as follows.
– For boot big band (and small band) without joint [A]:
Remove boot big band (and small band) by tapping
boot and band with plastic hammer. If it is hard to
remove boot big band (and small band), cut it using
a nipper or an iron saw with care not to damage
joint housing.
– For boot big band (and small band) with joint [B]:
Draw hooks of boot big band (and small band)
together and remove band.
1
I5RW0A230023-01
1
I5RW0A312006-02
I5RW0A312003-01

Downloaded from www.Manualslib.com manuals search engine 3A-17 Drive Shaft / Axle: Rear
Reassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following points which is different
from the front drive shaft is described.
• Apply grease to each joint.
Grease color
Wheel side: Black
Differential side: Dark gray
Amount
Wheel side: 50 – 70 g (1.8 – 2.5 oz)
Differential side: 70 – 90 g (2.5 – 3.2 oz)
• Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
• Fit differential side boot as follows.
– Fit boot (1) to grooves of shaft and housing (2)
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 and right side drive shafts “a”: 142.5
mm (5.61 in.)• Fasten differential side boot band as follows.
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.

– Place differential side boot new big band (3) and
new small band onto boot putting band outer end
(1) against forward rotation (2) as shown in figure.
– Fasten differential side boot new big band (1) and
new small band by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
(A)
1
I5RS0B310009-01
“a”
2
1I5RW0A312007-01
I5RW0A312004-01
(A)
1
4
2
3
I5RW0A312005-01