1998-2003 Suzuki Alto 4 Door Rear Suspension (Leaf Spring Type) User Manual
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Rear Suspension (Leaf Spring Type) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

3E
REAR SUSPENSION 3E-1
SECTION 3E
REAR SUSPENSION
(LEAF SPRING TYPE)
NOTE:
D All rear suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a re-
placement part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to assure proper retention of this part.
There is to be no welding as it may result in excessive damage and weakening of the metal.
D Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage
to the part may result.
CONTENTS
GENERAL DESCRIPTION 3E- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS 3E- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3E- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Shock Absorber Check 3E- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leaf Spring, Bump Stopper and Leaf Spring Bushes Check 3E- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Disk, Nut and Bearing Check 3E- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3E- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber 3E- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leaf Spring 3E- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle 3E- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bearing and Wheel Stud 3E-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS 3E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
Rear suspension consists of leaf springs, bump stoppers, and shock absorbers.
1. Leaf spring:
Apply silicone grease 99000-25190
to shackle pin bushes.
2. Bump stopper
3. Shock absorber
4. Rear axle:
Apply water tight sealant 366E 99000-31090
to joint seam of axle and brake back plate.
5. Wheel bearing
6. Brake drum
7. Spindle cap
8. Spindle nut
9. Split pin
10. U-bolt:
Tighten both front and rear U-bolts protrusion
becomes equal.
11. U-bolt nut
: Tightening Torque
: Do not reuse
3E-2 REAR SUSPENSION
DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.
REAR SHOCK ABSORBER CHECK
D Inspect for deformation or damage.
D Inspect bushings for wear or damage.
D Inspect for evidence of oil leakage.
Replace any defective part.
WARNING:
When handling rear shock absorber in which high-pres-
sure gas is sealed, make sure to observe the following
precautions.
1) Don’t disassemble it.
2) Don’t put it into the fire.
3) Don’t store it where it gets hot.
4) Before disposing it, be sure to drill a hole in it where
shown by an arrow in figure and let gas and oil out.
Lay it down sideways for this work.
5) The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. There-
fore, be sure to wear goggle.
Drill hole with approxi-
mately 3 mm
(0.12 in.) diameter.
LEAF SPRING, BUMP STOPPER AND LEAF
SPRING BUSHES CHECK
D Inspect for crack and damage. If found defective, replace. Also
inspect if the bump stopper is seated properly. If it is off its seat,
replace.
D Inspect for wear and breakage. If found defective, replace.
When shackle pin bush is not worn and yet abnormal sound is
noted while driving, remove bushes and apply silicone grease
to its periphery.
REAR SUSPENSION 3E-3
WHEEL DISC, NUT AND BEARING CHECK
D Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.
D Check wheel hub nuts for tightness and, as necessary, retighten
to specification.
Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
D Check wheel bearings for wear. When measuring thrust play,
apply a dial gauge to the drum center after removing wheel cen-
ter cap from wheel disc.
Thrust play limit “a”: 0.3 mm (0.012 in.)
When measurement exceeds limit, replace bearing.
D By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If it is defective, replace bearing.
3E-4 REAR SUSPENSION
ON-VEHICLE SERVICE
SHOCK ABSORBER
1. Shock absorber upper bolt
2. Shock absorber assembly
3. Upper lock washer
4. Upper nut
5. Lower bolt
6. Lower lock washer
7. Lower nut
: Tightening Torque
REMOVAL
1) Hoist vehicle.
2) Remove lower mounting bolt and nut.
3) Remove upper mounting bolt and nut. Then remove shock ab-
sorber.
INSTALLATION
1) Install shock absorber, referring to above figure.
2) Tighten nuts to specified torque.
Tightening torque for upper nut:
58 N·m (5.8 kg-m, 42.0 lb-ft)
Tightening torque for lower nut:
29 N·m (2.9 kg-m, 21.0 lb-ft)
3) Lower vehicle.
REAR SUSPENSION 3E-5
LEAF SPRING
1. Leaf spring
2. Bump stopper
3. Bump stopper bracket
4. Rear axle
5. Rear axle spring seat
6. U-bolt
7. Shackle pin
: Tightening Torque
REMOVAL
1) Raise vehicle. In this operation, garage jack or hoist must not
be positioned against rear suspension related parts. When ga-
rage jack is used, place safety stands under body to support
raised body. Or, where possible, raise vehicle body with body
contact type hoist until tires are off the floor.
NOTE:
Don’t let rear axle hang on brake hose. If it occurs, hose
may be damaged. To prevent it, always hold rear axle of
raised vehicle with safety stands.
2) Remove rear wheel.
3) Remove U-bolt nuts.
4) Remove shackle nuts and leaf spring front nut.
5) Pull out leaf spring front bolt and remove leaf spring from
shackle pin.
3E-6 REAR SUSPENSION
INSTALLATION
1) Before installing leaf spring, apply silicone grease by spreading
it hard into thin coat over the entire area. (Be sure to use silicone
grease that will not affect rubber.)
“A” : Silicone grease 99000-25190
2) Install front bolt (1) and shackle pins (2) in the direction as
shown. Tighten each nut to specified torque.
Tightening Torque
(a) : 58 N·m (5.8 kg-m, 42.0 lb-ft)
(b) : 43 N·m (4.3 kg-m, 31.0 lb-ft)
3) Place bump stopper (3) on leaf spring (4), aligning projection of
bump stopper to recess in spring.
Fit pin (5) (projection) on under side of leaf spring into hole in
spring seat (6) on rear axle.
Put through U-bolts (7) from bump stopper side to spring seat
side and tighten nuts to specified torque.
Tightening Torque
(c) : 38 N·m (3.8 kg-m, 27.5 lb-ft)
NOTE:
Tighten so that “a” and “b” becomes equal.
4) Install rear wheel and tighten nut to specified torque.
Tightening torque for wheel nut :
55 N·m (5.5 kg-m, 40.0 lb-ft)
5) Lower vehicle.
REAR SUSPENSION 3E-7
REAR AXLE
NOTE:
See NOTE at the beginning of this section.
In removing and installing rear axle, the same procedure is re-
quired on both the right and left sides. The procedure de-
scribed here is a representative one. If it is used on one side,
it must be used in symmetry on the other side.
REMOVAL
1) Hoist vehicle and remove rear wheels.
2) Pull brake drum. (Refer to WHEEL BEARING AND WHEEL
STUD in this section.)
3) Remove brake shoe, refer to BRAKE SHOE in Section 5.
4) Remove E-ring (1) and brake hose/pipe (2) from bracket on
axle.
5) Disconnect brake pipe flare nut (3) from wheel cylinder and put
breeder plug cap onto brake pipe to prevent brake fluid outflow.
6) Remove brake hose/pipe from bracket on axle.
7) Remove parking brake cable securing clip and disconnect park-
ing brake cable from brake back plate.
8) Remove brake back plate (1) by removing bolts (2).
9) Remove shock absorber lower mount bolt.
10) Remove U-bolt nuts (3), U-bolts (2) and bump stopper (1).
11) Remove rear axle.
3E-8 REAR SUSPENSION
INSTALLATION
1) Place bump stopper (2) on leaf spring (4), aligning projection of
bump stopper to recess in spring.
2) Fit pin (7) (projection) on under side of leaf spring into hole (8)
in spring seat (6) of rear axle (1).
3) Tightening U-bolt nuts (5) to specified torque.
Tightening Torque
(a) : 38 N·m (3.8 kg-m, 27.5 lb-ft)
NOTE:
Tightening U-bolt (3) so that “a” and “b” becomes equal.
REAR SUSPENSION 3E-9
4) Apply water tight sealant to joint seam of axle and mating sur-
faces of brake back plate.
“C” : Sealant 366E, 99000-31090
5) Install brake back plate to rear axle and tighten back plate bolts
to specified torque.
Tightening Torque
(b) : 23 N·m (2.3 kg-m, 16.5 lb-ft)
6) Put brake hose/pipe through hole in bracket on axle and se-
cure it with E-ring (3) and remove breeder plug cap (1) from
end of pipe. Then tighten pipe flare nut (4) to wheel cylinder (2)
to specified torque.
Tightening Torque
(c): 16 N·m (1.6 kg-m, 11.5 lb-ft)
7) Apply water tight sealant where plate and cable contact, and
run parking brake cable through back plate and secure it with
clip, refer to BRAKE BACK PLATE in Section 5.
8) Install brake shoe, refer to BRAKE SHOE in Section 5.
9) Install brake drum. (Refer to WHEEL BEARING AND WHEEL
STUD in this section.)
10) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to BLEEDING BRAKES in Section
5.)
11) Upon completion of all jobs, depress brake pedal with about
30kg (66 lbs) load two to three times so as to obtain proper
drum-to-shoe clearance.
12) Check to make sure that brake drum is free from dragging and
brake works properly. Then lower vehicle from lift and perform
brake test.
3E-10 REAR SUSPENSION
WHEEL BEARING AND WHEEL STUD
REMOVAL
1) Hoist vehicle and remover rear wheel.
2) Remove spindle cap (1) as shown (by hammering lightly at 3
locations around it so as not to deform or cause damage to seat-
ing part of cap).
3) Remove split pin (1), castle nut (2) and washer (3).
4) Release parking brake lever (1) to cancel rear brake.
5) Loosen parking brake cable lock nuts (2).
FRONT
REAR SUSPENSION 3E-11
2) Install wheel bearing by using special tool.
Special Tool
(A) : 09913-76010
NOTE:
When installing bearings:
D Direct stamped side of bearing towards outside.
D Refer to figure for installing direction of spacer (1).
D Direct inner bearing sealed side (2) outward.
D Fill the space indicated by “A” in figure with bearing
grease as much as 40% of space capacity.
D Install outer bearing (3) so that resin side of its retainer
faces toward the outside of vehicle body.
3) Remove back plate plug attached to the back side of brake back
plate so as to increase clearance between brake shoe and
brake drum. Insert flat head rod or the like till its tip is in the gap
between strut and adjust lever and turn it clockwise a little so
that shoe adjust lever moves. Thus shoe-to drum clearance can
be increased.
4) Install brake drum after making sure that inside of brake drum
and brake drum and brake shoe are free from dirt and oil.
5) Install washer (3) and spindle nut (2).
6) Tighten spindle nut to specified torque.
Tightening Torque
(a) : 100 N·m (10.0 kg-m, 72.5 lb-ft)
7) Bend split pin (1) securely.
REAR SUSPENSION 3E-13
8) Install spindle cap.
NOTE:
D When installing spindle cap, hammer lightly several
locations on the collar of cap unit the collar comes
closely into contact with brake drum.
D If fitting part of cap is deformed or damaged or if it is
fitted loosely, replace with new one.
9) Tighten wheel nuts to specified torque.
Tightening Torque
(b) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
10) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load two to three times so as to obtain proper
drum-to-shoe clearance.
11) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test.
3E-14 REAR SUSPENSION
REAR SUSPENSION 3E-15
REQUIRED SERVICE MATERIALS
MATERIALS
RECOMMENDED
SUZUKI PRODUCT
USE
Brake fluid DOT3 Brake reservoir tank
Water tight sealant
SEALING COMPOUND 366E
(99000-31090)
Joint seam of rear axle and brake back plate
–
SILICONE GREASE
(99000-25190)
By spreading leaf spring hard into thin coat over
the entire area.
SPECIAL TOOLS
09913-76010
Rear wheel bearing
installer
09942-15510
Sliding hammer
09943-17912
Brake drum remover

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