Get Front Drive Shaft -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

ON-VEHICLE SERVICE

DRIVE SHAFT ASSEMBLY

REMOVAL

1) Undo caulking and remove drive shaft nut (1) and washer.

A: Undo caulking

2) Hoist vehicle.

3) Remove wheel.

4) Remove tie-rod end split pin (1) and castle nut (2).

5) Disconnect tie-rod end (3) from steering knuckle (4) by using

special tool.

Special Tool

(A): 09913-65210

6) Drain transmission fluid.

7) Using large size lever (1), pull out drive shaft joint (2) so as to

release snap ring fitting of joint spline at differential side.

8) Disconnect front suspension control arm ball stud (1) from

steering knuckle (2) by pushing down stabilizer bar (4) after re-

moving stud bolt (3).

9) Remove drive shaft assembly.

CAUTION:

To prevent breakage of boots, be careful not to bring

them into contact with other parts, when removing

drive shaft assembly.

FRONT DRIVE SHAFT 4-3

DISASSEMBLY

1) Wipe outer surface of drive shaft with a cloth and disassembly

in the following manner.

2) Remove boot band (1) of differential side joint.

3) Slide boot (1) toward the center of shaft and remove snap ring

(2) from outer race (3).

4) Wipe off grease and remove circlip (1) used to fix cage (2) by

using special tool and then remove cage and boot (3) from

shaft.

Special Tool

(A): 09900-06107

NOTE:

Do not disassemble wheel side joint (outboard joint). If any

malcondition is found in any joint, replace it as assembly.

INSPECTION

D Inspect boots for breakage or deterioration.

Replace them as necessary.

D Inspect circlip, snap ring and boot bands for breakage or deterio-

ration. Replace as necessary.

4-4 FRONT DRIVE SHAFT

ASSEMBLY

1) Fit a boot (1) on drive shaft and, fitting small diameter side of the

boot to shaft groove, fix with a boot band (2).

CAUTION:

Wash all part before installation. Wipe out boot with a

cloth.

2) Install cage (1) on drive shaft.

Diameter : A > a

CAUTION:

Install the cage directing the smaller outside diameter

side to the shaft end.

3) Install circlip (1) by using special tool.

Special Tool

(A): 09900-06107

4) Apply grease to entire surface of cage.

“A” : SUZUKI SUPER GREASE H 99000-25120

5) Insert cage into outer race (2) and fit a snap ring (1) in the groove

of outer race.

CAUTION:

Locate the opening of the snap ring “b” so that the

opening is not lined up with a ball.

FRONT DRIVE SHAFT 4-5

6) Apply grease to inside of outer race (1) and fit boot (2) to outer

race. After fitting boot, insert screwdriver into boot on outer race

side and allow air to enter boot so that air pressure in boot be-

comes the same as atmospheric pressure.

7) When fixing boot band, adjust so that measurements “C” be-

come as specified.

Length “C” : 77 – 87 mm (3.03 – 3.43 in.) for right side joint

74 – 84 mm (2.91 – 3.31 in.) for left side joint

CAUTION:

D To prevent any problem caused by washing solu-

tion, do not wash joint boots and tripod joint except

its housing. Degreasing of those parts with cloth is

allowed.

D 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. Refer to the previous page for identification of

the grease.

D Bend each boot band against forward rotation.

D Do not squeeze or distort boot when fastening it

with bands.

Distorted boot caused by squeezing air may reduce

its durability.

“A” : Fill grease 60 – 90 g (2.1 – 3.2 oz)

“B” : Fill grease 50 – 75 g (1.8 – 2.6 oz)

4-6 FRONT DRIVE SHAFT

INSTALLATION

Install drive shaft assembly by reversing removal procedure and

noting following points.

D Clean front wheel bearing oil seal (1) and then apply grease.

Replace it if required.

“A”: SUZUKI SUPER GREASE A 99000-25010

CAUTION:

D To avoid excessive expansion of boot and consequen-

tial disconnection of joint in boot, do not pull differen-

tial side joint housing.

D Protect oil seals and boots from any damage, prevent-

ing them from unnecessary contact while installing

drive shaft.

D Do not hit joint boot with hammer. Inserting joint only

by hands is allowed.

D Make sure that differential side joint is inserted fully

and its snap ring is seated as it was.

D Tighten each bolt and nut to the specified torque.

Tightening Torque

(a): 21 N·m (2.1 kg-m, 15.5 lb-ft) For 5-speed transmission

28 N·m (2.8 kg-m, 20.5 lb-ft) For 4-speed transmission

(b): 21 N·m (2.1 kg-m, 15.5 lb-ft) For 5-speed transmission

only

(c): 55 N·m (5.5 kg-m, 40.0 lb-ft)

(d): 175 N·m (17.5 kg-m, 127.0 lb-ft)

(e): 43 N·m (4.3 kg-m, 31.0 lb-ft)

(f): 55 N·m (5.5 kg-m, 40.0 lb-ft)

D Apply sealant to drain plug (1) for manual transmission.

“B”: Sealant 99000-31110

D Fill transmission with oil as specified. (Refer to Section 7A or

7B.)

D Install split pin to tie-rod end castle nut (2).

FRONT DRIVE SHAFT 4-7

Front Drive Shaft -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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