Front Axle Housing Removal and Installation
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.
During removal, be careful not to damage brake flexible hose and not to depress brake pedal.
5) Remove right and left brake disc.
If brake disc can not be removed by hand, use 8 mm bolts (1).
6) Remove wheel speed sensor (if equipped with ABS).
7) Disconnect spindle vacuum hoses from wheel spindle (for 4WD).
Give match mark to spindle vacuum hose and wheel spindle before removal.
1. Vacuum hose to lock 2. Vacuum hose to unlock
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
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.
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.
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).
At this time, lower kingpin bearing sometimes falls off.
So remove bearing while pulling off knuckle gradually.
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 Removal and Installation .
17) Remove stabilizer bar, refer to Front Stabilizer Bar and Bushings Removal and Installation .
18) Loosen mounting nuts of leading arm (1) but don't remove bolts.
19) Lower floor jack until tension of suspension coil spring becomes a little loose and remove right and left sides lower mounting bolt of shock absorber (1).
20) Remove front mounting bolts of leading arm.
21) Lower front axle housing gradually.
22) Remove axle housing.
1) Place rear axle housing on floor jack. Then install leading arm front mounting bolts (right & left) in proper direction as shown. At this time, mount nuts but don't tighten them.
A: Body outside
2) Install lower part of shock absorber (1) to right and left sides of axle housing and install bolts (2) in proper direction as shown in the figure. At this time, mount nuts (3) but don't tighten them.
3) Install air locking hub vacuum pipe and tighten clamp bolts to specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolt ( a ): 5.5 N·m ( 0.55 kg-m, 4.0 lb-ft)
4) Install stabilizer bar, refer to Front Stabilizer Bar and Bushings Removal and Installation .
5) Install lateral rod (1) to vehicle body and axle housing.
Install bolts in proper direction as shown in the figure.
At this time, mount bolt and nut but don't tighten them.
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
6) Clean mating surfaces of axle housing (1) and differential carrier and apply sealant to housing side (for 4WD).
“A” : Sealant 99000–31110 ( SUZUKI Bond No.1215 )
7) Install differential carrier assembly (2) to axle housing and tighten carrier bolts to specified torque (for 4WD).
Tightening torque
Front differential carrier bolt ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
8) Install front propeller shaft (1) to joint flange aligning match marks (3) and torque flange bolts to specification (for 4WD).
Tightening torque
Front propeller shaft flange bolt ( b ): 50 N·m ( 5.0 kg-m, 36.5 lb-ft)
9) Install right and left axle shafts to axle housing (for 4WD). Install knuckle to axle housing (for 2WD).
Place knuckle seal and retainer in axle housing before installing axle shaft (knuckle), using care for installation direction of knuckle seal.
10) Install kingpins (2) and knuckle seal cover (1) to steering knuckle (R&L), refer to Steering Knuckle / Wheel Spindle Removal and Installation:Front .
11) Install right and left brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolt ( 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.
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.
Tightening torque
Tie rod end nut 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 nut : 100 N·m ( 10.2 kg-m, 74.0 lb-ft)
16) Lower hoist.
17) Tighten lateral rod (1) mounting bolt and nut to specified torque referring to Lateral Rod Removal and Installation .
18) Tighten right and left shock absorber lower mounting nuts and leading arm mounting nuts to specified torque. Refer to Front Shock Absorber Removal and Installation and Leading Arm / Bushing Removal and Installation .
19) Refill front axle (differential) housing with new specified gear oil. Refer to Front Differential Gear Oil Inspection and Change:Front .
20) Confirm front end (wheel) alignment referring to Preliminary Checks Prior to Adjustment Front Wheel Alignment Construction .