2006 SUZUKI SX4 front drive shaft assembly

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-34
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation
S6RW0D3206010
Remove and install front mounting arm and/or rear
mounting bracket after rear differential removed.
For tightening torque of each bolt and nut, refer to “Rear
Differential Mountings Components”.
Rear Mounting Bracket Assembly Disassembly
and Reassembly
S6RW0D3206011
Disassembly
Drive out mountings from rear mounting bracket using
special tool and hydraulic press.
Special tool
(A): 09913–70123
(B): 09951–26020
Reassembly
Press mountings in rear mounting bracket using special
tool and hydraulic press with caring its installation
position shown in figure.
Special tool
(A): 09913–85210
(B): 09951–26020
Rear Differential Dismounting and RemountingS6RW0D3206012
Dismounting
1) Lift up vehicle and drain oil from rear differential.
2) Remove propeller shaft referring to “Propeller Shaft
Assembly Removal and Installation in Section 3D”.
3) Remove rear drive shafts assembly referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
4) Support rear differential (3) with transmission jack
(4).
5) Remove mounting arm bolts (2) and rear mounting
bolts (1), and then lower rear differential with rear
mounting bracket.
Remounting
Reverse dismounting procedure for remounting of rear
differential, noting the following points.
• Tighten each bolt to specified torque referring to “Rear
Differential Mountings Components”.
• Fill gear oil to rear differential referring to “Rear
Differential Oil Change”.
(B)
(A)
I5RW0A320023-02
(A)
(B)
I5RW0A320024-02
3
4 21
I5RW0A320025-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-36
Rear Differential Disassembly and ReassemblyS6RW0D3206014
Disassembly
1) Remove rear mounting bracket from rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
2) Remove drive shaft flanges.
3) Separate coupling case from differential carrier using
special tool.
Special tool
: 09912–34510
4) Hold companion flange with special tool and then
remove flange nut.
Special tool
(A): 09930–40113
5) Remove companion flange (1) from pinion. Use
special tool if it is hard to remove.
Special tool
(A): 09913–651356) Remove coupling assembly (1) by using hydraulic
press.CAUTION!
Do not drop coupling assembly. If it is
dropped, replace it with a new one.

7) Disassemble coupling case as follows, if necessary.
a) Remove oil seal using special tool.
Special tool
(A): 09913–50121
b) Remove snap ring using snap ring pliers.
c) Remove bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
(A)
I5RW0A320027-01
(A)
1
I5RW0A320028-01
1
I5RW0A320029-01
(A)
I5RW0A320030-01
(A)
I5RW0A320031-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-38
14) Using a hammer and brass bar (1), drive out front
bearing outer race (2).
15) Using a hammer and brass bar (1), drive out rear
bearing outer race (2).
Reassembly
Judging from faulty conditions noted before disassembly
and what is found through visual check of bearing and
gear tooth etc. after disassembly, prepare replacing
parts and proceed to reassembly according to
procedures as described in the following.
CAUTION!
• Bevel gear and pinion must be replaced as
a set when either replacement becomes
necessary.
• When replacing taper roller bearing,
replace as inner race & outer race
assembly.

1) Press-fit bevel pinion bearing outer races to
differential carrier (1) by using special tools and
hydraulic press as shown in the figure.
Special tool
(A): 09913–85210
(B): 09913–75510
2) After applying differential oil to differential gears (4),
pinions (5), pinion shaft (3), side washers (1), spring
washers (7) and pinion washers (2), install them in
differential case (6).
For correct installing direction of side washers and
spring washers, refer to figure.
NOTE
Used left and right differential side washers
are not interchangeable.

3) Check pinion gear (1) for smooth rotation.
1
2
I5RW0A320038-01
1
2
I5RW0A320039-01
(B)(A)
1
I5RW0A320040-02
7 6
4
5
3
21
I5RW0A320041-01
I3RH01322031-01

Downloaded from www.Manualslib.com manuals search engine 3B-47 Differential:
31) Clean mating surface of differential carrier (1) and
coupling case (2), apply sealant to carrier as shown
in figure by such amount that its section is 1.5 mm
(0.059 in.) in diameter, mate coupling case with
differential carrier as shown in figure, and then
tighten bolts to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Coupling case bolt (a): 23 N·m (2.3 kgf-m, 17.0
lb-ft)
NOTE
Install coupling pin (3) by fitting it to groove
(4) of coupling case.

32) Apply grease to oil seal lip, and then install oil seals
(1) to rear differential (2) using special tool as shown
in figure.
NOTE
Install oil seal horizontally to surface of rear
differential case.

“A”: Grease 99000–25010 (SUZUKI Super
Grease A)
Distance between rear differential and oil seal
“a”
: 1.0 – 2.0 mm (0.04 – 0.08 in.)
Special tool
(A): 09913–75810
33) Install drive shaft flange.
34) Install rear mounting bracket to rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
Rear Differential InspectionS6RW0D3206015
• Check companion flange for wear or damage.
• Check bearings for wear or discoloration.
• Check differential carrier for cracks.
• Check drive bevel pinion and bevel gear for wear or
cracks.
• Check side gears, pinion gears and pinion shaft for
wear or damage.
• Check side gear spline for wear or damage.
1 4
3 2“A”
(a)
I5RW0A320062-04
(A)
2 21, “A”
“a”
I5RW0A320063-02

Downloaded from www.Manualslib.com manuals search engine 3C-3 Transfer:
Transfer Dismounting and RemountingS6RW0D3306003
Dismounting
1) Disconnect negative cable at battery.
2) Drain transaxle oil and transfer oil.
3) Remove drive shafts assembly referring to “Front
Drive Shaft Assembly Removal and Installation in
Section 3A”.
4) Remove exhaust No.1, No.2 and center pipes
referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
5) Remove suspension frame, engine front mounting
member and mounting member referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B” and “Engine
Assembly Removal and Installation in Section 1D”.
6) Remove engine rear mounting bracket (1) and
stiffeners (2) from transfer.
7) Support transfer with transmission jack.
8) Remove transfer to transaxle bolts (1), and then
lower transfer assembly (2).Remounting
Reverse dismounting procedure for remounting of
transfer, noting the following points.
• Apply grease to left case (1) as shown in figure.
“A”: Grease 99000–25010 (SUZUKI Super Grease
A)
• Tighten engine rear mounting bracket nut to specified
torque referring to “Engine Mountings Components in
Section 1D”.
• Tighten bolts to specified torque as follows.
Tightening torque
Stiffener No.1 bolt and No.2 bolt (a): 55 N·m (5.5
kgf-m, 40.0 lb-ft)
Transfer to transaxle bolt (b): 98 N·m (9.8 kgf-m,
71.0 lb-ft)
2
2
1I5RW0A330004-01
1
1
2
I5RW0A330005-02
I5RW0C330001-01
(a)
(a)
(b)
(b)
2
I5RW0A330006-02

Downloaded from www.Manualslib.com manuals search engine 3C-5 Transfer:
Transfer Assembly Disassembly and
Reassembly
S6RW0D3306005
Disassembly
NOTE
It is possible to disassemble transfer
assembly without removing intermediate
shaft with Step 1) to 4) performed if not
necessary.

1) Remove right case oil seal No.1 (1) from transfer
right case using special tool.
Special tool
: 09913–50121
2) Remove snap ring (2) by using snap ring pliers.
3) Remove intermediate shaft (4) with intermediate
shaft bearing (3) from transfer assembly.
4) Remove intermediate shaft bearing (3) from
intermediate shaft (4) by using bearing puller and
hydraulic press.
5) Remove transfer output retainer assembly (1) and
shim (3) by removing retainer bolts (2).
6) Remove transfer case bolts (4).
7) Separate transfer right case (5) from transfer left
case (6) by using special tool.
Special tool
(A): 09912–34510
8) Remove reduction drive gear assembly (7) and
reduction driven gear assembly (9).
9) Remove shim (10) and bearing outer races (8).
NOTE
When it is difficult to remove bearing outer
races from cases, remove them with special
tool.

Special tool
(B): 09944–96011Reassembly
1) Select appropriate shim as follows.
a) Measure distance “a” between taper roller
bearing outer races of reduction driven gear
assembly (1).
b) Measure depth “b” of left case (2) and “c” of right
case (3).
c) Obtain adjusting shim thickness by the following
equation.
9. Pump seal 23. Reduction drive gear right bearing : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
10. Pinion shaft front taper roller bearing 24. Intermediate shaft : 21 N⋅m (2.1 kgf-m, 15.5 lb-ft)
11. Bevel pinion 25. Oil protect plate bolt
: Apply thread lock cement 99000-32110
to thread part.: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
12. Bevel gear 26. Snap ring : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
13. Reduction driven gear 27. Oil protect plate : Do not reuse.
14. Intermediate shaft bearing 28. Shim : Apply transfer oil.
4
3
2
1
I5RW0A330008-01
11. Dowel pin
Necessary
shim
thickness=Depth
“b”+Depth
“c”–Distanc
e “a”+0.1 mm
(0.004
in.)
7
(B)
5
11
310 9 10
8 64
8
(A)
12
2
I5RW0A330009-03
23
1
“b”
“a”“c”
I5RW0A330010-01

Downloaded from www.Manualslib.com manuals search engine 4E-37 ABS:
Front Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506010
Before inspecting front wheel speed sensor encoder,
remove front drive shaft referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check sensor encoder (1) for crack, damage or
deformation.
• Turn wheel and check if sensor encoder rotation is
free from eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Front
Wheel Hub, Steering Knuckle and Wheel Bearing
Removal and Installation in Section 2B”.
Front Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506011
CAUTION!
Front wheel speed sensor encoder is
included in front wheel hub assembly. If front
wheel speed sensor encoder needs to be
replaced, replace it as a front wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Front Wheel Hub, Steering
Knuckle and Wheel Bearing Removal and Installation in
Section 2B”.
Rear Wheel Speed Sensor Encoder On-Vehicle
Inspection
S6RW0D4506012
For 4WD model
Refer to “Rear Wheel Speed Sensor On-Vehicle
Inspection”.
For 2WD model
Before inspecting rear wheel speed sensor encoder,
remove rear wheel speed sensor referring to “Rear
Wheel Speed Sensor Removal and Installation (2WD
Model)”.
• Check encoder (1) for crack, damage or deformation.
• Turn wheel and check if encoder rotation is free from
eccentricity and looseness.
• Check that no foreign material is attached.
If any faulty is found, clean or replace. Refer to “Rear
Wheel Hub Assembly Removal and Installation in
Section 2C”.
Rear Wheel Speed Sensor Encoder Removal
and Installation
S6RW0D4506013
CAUTION!
Rear wheel speed sensor encoder is included
in rear wheel hub assembly. If rear wheel
speed sensor encoder needs to be replaced,
replace it as a rear wheel hub assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Assembly
Removal and Installation in Section 2C”.
1
I5RW0A450026-01

Downloaded from www.Manualslib.com manuals search engine 5A-4 Automatic Transmission/Transaxle:
I5RW0C510070-01
1. Drive plate 11. 1st and reverse brake 21. Rear sun gear
2. Torque converter clutch (TCC) 12. Ring gear 22. Front sun gear
3. Torque converter 13. Long planet pinion 23. Short planet pinion
4. Input shaft 14. One-way No.2 clutch 24. Countershaft
5. Oil pump 15. 2nd brake 25. Reduction driven gear
6. Direct clutch drum (double as sensor rotor for input shaft
speed sensor)16. One-way No.1 clutch 26. Differential case assembly
7. Direct clutch 17. O/D and 2nd coast brake 27. Final gear
8. Parking lock gear 18. Intermediate shaft 28. Output shaft speed sensor (VSS) drive gear
9. Reduction drive gear 19. Forward clutch
10. Planet carrier 20. Reverse clutch