Universal Joint Disassembly and Reassembly - Suzuki Jimny Workshop Manual

1) Using special tool, remove 4 circlips (1).

2) Apply penetrate lubricant between bearing race outer diameter and shaft yoke bore.

3) Using a set of special tool, push spider bearing race (1) out 3 – 4 mm (0.12 – 0.16 in.) from shaft yoke side face (2).

4) Tapping shaft yoke (2) with a hammer, remove bearing race (1) from shaft yoke (2) completely.

5) Take out bearing race (1) on the opposite side of shaft yoke (2) in the same way as shown.

6) Push out bearing race (2) on flange yoke (1) in the same way as Step 2).

7) Holding bearing race (2) by a vise (3), tap flange yoke (1) and take out race.

8) Take out bearing race (2) on the opposite side of flange yoke (1) in the same way as Step 5) to Step 6).

1) Apply grease to rollers (1) in bearing races (2).

2) With spider (4) inserted into bearing race (2) to prevent rollers in race from coming out, insert bearing race (2) into shaft yoke (3) until it is flush with side face of shaft yoke (3), tapping it by a copper hammer (1).

3) Insert bearing race into opposite side of shaft yoke until it is flush with side face of shaft yoke, tapping it by a copper hammer.

4) In the same way as Step 2) to Step 3), insert bearing races into flange yoke.

5) Using round bar of 22 – 24 mm (0.87 – 0.94 in.) in diameter and hammer, tap bearing races into shaft or flange yoke until circlips can be installed in its groove on yoke bores.

6) Install 4 circlips in each groove on shaft and flange yoke bores.