Cv joint SUZUKI SWIFT 2006 2.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine 3A-6 Drive Shaft / Axle:
Front Drive Shaft Disassembly and ReassemblyS7RS0B3106004
Disassembly
Tripod joint
CAUTION!
• Disassembly of wheel side joint is not allowed. If any noise or damage exists in it,
replace it as assembly.
• Do not disassemble tripod joint spider. If any malcondition is found in it, replace it
as differential side joint assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint:Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint: Draw hooks of boot big band together and remove
band. 2) Wipe off grease from shaft and take off snap ring (1)
using snap ring pliers (2).
3) Remove tripod joint spid er (1) using 3 arms puller
(2).
CAUTION!
To prevent any problem caused by washing
solution, do not wash tripod joint except its
housing. Degreasing of tr ipod joint with cloth
is allowed.

4) Remove boot band as follows.
a) Remove differential side (or center shaft side) boot small band, and then pull out differential
side (or center shaft side) boot from shaft.
b) Remove damper band, and then pull out damper through shaft, if equipped.
c) Undo caulking (5) of wheel side boot big band (1) and small band (3) using flat end rod (2) or the
like, then pull out wheel side boot (4) from shaft.
[A]: For boot big band without joint
[B]: For boot big band with joint
I4RH0A310004-01
I5JB0A311008-01
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I4RS0A310006-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-7
DOJ
CAUTION!
Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.

1) Remove differential side (or center shaft side) boot big band (1) as follows.
• For boot big band without joint:Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint: Draw hooks of boot big band together and remove
band.
2) Remove differential side (or center shaft side) boot small band (1) using flat end rod (2) or the like.
3) Side boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out
of outer race (3). 4) Wipe off grease and remove circlip (1) used to fix
cage (2) by using snap ring pliers (3).
5) Draw away cage (1) by using bearing puller (2), and remove boot (3) from shaft.
6) Pull out differential side (or center shaft side) boot from shaft.
7) Undo caulking (5) of wheel side boot big band (1) and small band (3) using flat end rod (2) or the like,
then pull out wheel side boot (4) from shaft.
[A]: For boot big band without joint
[B]: For boot big band with joint
I4RH0A310004-01
2
1
I5RS0B310005-01
I2RH01310012-01
I5RS0B310006-01
I2RH01310014-01
I4RS0A310006-01

Downloaded from www.Manualslib.com manuals search engine 3A-8 Drive Shaft / Axle:
Reassembly
Tripod joint
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly (1) and tripod
joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• 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
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After washing, dry parts comp letely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-9
7) Fasten boot bands (1) securely using special tool as
shown in figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 55 in.)
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Special tool
(A): 09943–57010 8) Set new differential side (or center shaft side) small
band and new differential side (or center shaft side)
boot (1) on shaft temporarily, and then apply grease
to tripod joint (2). Use specified grease in tube
included in spare parts.
9) Install tripod joint spider (3) on shaft using special
tool with hammer, directing its chamfered spline
toward wheel side, and then fasten it with new snap
ring (4) using snap ring pliers (5).
Special tool
(A): 09925–98221
10) Apply grease (including in spare parts) to inside of tripod joint housing (1), jo int it with tripod joint.
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz)
(A)
1
(A)
1
“a”
1
I5RS0B310008-01
I5JB0A311009-01
I4RS0B310003-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-11
DOJ
Judging from abnormality noted before disassembly and
what is found through visual check of components parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly and DOJ
housing are washed thoroughly and air dried.
Replace boot(s) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• 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
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside wi th specified grease.
6) Fit boot (1) to grooves of shaft and housing (2).
7) Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
8) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure. 9) Fasten boot bands (1) using special tool as shown in
figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Special tool
(A): 09943–57010
21I5RS0B310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine 3A-12 Drive Shaft / Axle:
10) Set new differential side (or center shaft side) small band and new differential side (or center shaft side)
boot on shaft temporarily.
11) Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
12) Install circlip (1) by using snap ring pliers (2).
13) Apply grease to entire su rface of cage. Use specified
grease in tube included in spare parts.
14) Insert cage into joint housing (2) and fit snap ring (1) into groove of joint housing (2).
CAUTION!
Position opening of snap ring “c” so that it
will not be lined up with a ball.

15) Apply grease (including in spare parts) to inside of joint housing (1).
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz) 16) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
17) Inset screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between boot end (housing side) and small boot
band center)
Left side and right side drive shafts “a”: 89.5 mm
(3.52 in.)
CAUTION!
• Band each boot band against forward rotation.
• Do not squeeze or distort boot when fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

(A)
1
I5RS0B310009-01
I5RS0B310010-01
I2RH01310036-01
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I5RS0B310011-02
I5RS0B310012-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-1
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS7RS0B4100001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS7RS0B4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and two in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake type is used for the front wheel brake and the rear wheel brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes or pads are used for both parking and foot brakes.
A
5
3
2
1
4
8
8
6
7
I6RS0C410001-01
1. Brake booster 4. Primary side 7. Parking brake lever
2. Master cylinder 5. 4 way joint 8. Parking brake cable
3. Secondary side 6. ABS or ESP® hydraulic unit / control module assembly A: Forward

Downloaded from www.Manualslib.com manuals search engine 4A-4 Brake Control System and Diagnosis:
Rear Brake Hose / Pipe ConstructionS7RS0B4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS7RS0B4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at vari ous speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes. Brake Fluid Leaks
Check the master cylinder fl
uid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low leve l indicates a leak in the
system. In such a case, chec k the entire brake system
for leakage. If even a slight ev idence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.
Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components in
the hydraulic system to deteriorate.
[A]: ABS model 6. Master cylinder13. ESP® hydraulic unit
[B]: ESP ® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft)
1. From master cylinder primary to hydraulic unit 8. From hydraulic unit to 4-way joint left: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
2. From master cylinder secondary to hydraulic unit 9. 4-way joint: 16 N⋅m (1.6 kgf-m, 11.5 lb-ft)
3. From hydraulic unit to right front brake 10.4-way joint to left rear brake hose : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
4. From hydraulic unit to left front brake 11. 4-way joint to right rear brake hose
5. ABS hydraulic unit 12. Master cylinder fixing nut
I6RS0C410003-01
A: View A4. Right rear brake hose8. Flexible hose joint bolt
1. To left rear brake hose 5. Left rear brake hose to left brake9. Caliper
2. To right rear brake hose 6. Right rear brake hose to right brake: 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
3. Left rear brake hose 7. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-9
Air Bleeding of Brake SystemS7RS0B4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper farthest from master cylinder
and then at front caliper of the same brake
line. Do the same on the other brake line.

1) Fill master cylinder rese rvoir with brake fluid and
keep at least one-half full of fluid during bleeding
operation.
Brake fluid
: Refer to reservoir cap (1) 2) Remove bleeder plug cap. Attach a vinyl tube (1) to
bleeder plug, and insert the other end into container
(2).
3) Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cy linder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug referring to “Front Disc
Brake Components in Section 4B” and “Rear Disc
Brake Components in Section 4C”.
1. Right front brake caliper 3. Right rear brake caliper
2. Left front brake caliper 4. Left rear brake caliper
I6RS0C410007-01
1
I6RS0C410009-01
I2RH01410015-01
I2RH01410016-01
I2RH01410017-01

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-1
Brakes
Front Brakes
Repair Instructions
Front Disc Brake ComponentsS7RS0B4206001
11
5
6
10
4
1
16
17
12
8
7
3
2(a)
15
(b)
14(c)2(a)
13
(d)
9
FLD
I6RS0C420005-02
1. Caliper 9. Disk brake piston
: Apply brake fluid to contact surface of cylinder. 17. Brake flexible hose
2. Caliper pin bolt 10. Pad spring : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)
3. Boot 11. Brake disc: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Slide pin : Apply rubber grease (included in slide pin boot set). 12. Brake caliper carrier
: 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
5. Brake pad 13. Caliper carrier bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
6. Shim : Apply small amount of pad grease (include in pad
repair kit). 14. Bleeder plug
: Do not reuse.
7. Cylinder boot : Apply small amount of rubber grease included in
piston seal set. 15. Flexible hose joint bolt
8. Piston seal : Apply small amount of rubber grease included in
piston seal set. 16. Hose washer