4WD SUZUKI JIMNY 2005 3.G Service Owner's Manual

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5) Apply lithium grease to lip portion and hollow of oil seal (1).
“A” : Grease 99000-25010
6) Install sensor rotor (3) as shown (if equipped with ABS).
7) Apply lithium grease inside wheel bearing thin.
“A” : Grease 99000-25010
8) Install wheel hub complete with bearings and oil seal onto
front wheel spindle.
9) Install bearing washer.
10) Tighten wheel bearing lock nut to specified torque while turn-
ing wheel hub by hand.
Special tool
(A) : 09944-77020 (For 4WD)
(A) : 09951-16050 (For 2WD)
Tightening torque
Wheel bearing lock nut
(a) : 220 N·m (22.0 kg-m, 160 lb-ft)
11) Install hub cap (for 2WD model) or air locking hub assembly
(for 4WD model) as follows. NOTE:
Amount of grease applied to hollow in oil seal (1) should
be more than 60% of its vacant space.
2. Wheel hub
NOTE:
Pipe (2) used here should have inner diameter of
90 mm (3.55 in.) – 96 mm (3.77 in.) and its outside
should not contact teeth of sensor rotor (3).
Use care not to insert wheel hub (4) diagonally.
1. Steel plate
5. Hydraulic press

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For 2WD model:
a) Using lock plate (1), lock bearing lock nut. If lock screw hole
is not aligned with screw hole in lock nut, turn lock nut in
tightening direction till they align.
Tightening torque
Wheel bearing lock washer screw
(a) : 1.5 N·m (0.15 kg-m, 1.0 lb-ft)
b) Remove grease, old sealant and dusts from mating sur-
faces of hub cap (1) and wheel hub (2) to clean, apply
water tight sealant to hub cap mating surface evenly, and
install hub cap (1) to wheel hub (2).
“A” : Sealant 99000-31090
For 4WD model:
a) Caulk front wheel bearing lock nut at groove of spindle.
b) Apply lithium grease thinly to both surface, all around of
front spindle thrust washer (1).
“A” : Grease 99000-25010
NOTE:
When installing hub cap (1), hammer lightly several
locations on the collar of cap until collar comes closely
into contact with wheel hub (2).
If fitting part of cap is deformed or damaged or if it is
fitted loosely, replace with new one.

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c) Install front axle shaft circlip (1) and apply thin coat of
grease to spline part of axle shaft.
“A” : Grease 99000-25010
d) Clean mating surface of air locking hub and wheel hub.
Install air locking hub assembly to wheel hub and tighten
bolts to specified torque.
Tightening torque
Air locking hub bolts
(a) : 48 N·m (4.8 kg-m, 35.0 lb-ft)
12) Install ABS wheel sensor (if equipped with ABS).
13) Install brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
14) Install wheel and tighten wheel nuts specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
15) Lower hoist.
16) For 4WD model:
Check air locking hub for air leakage, refer to “4WD System
Check” in this section. NOTE:
When installing circlip (1) to front axle shaft, utilize screw
hole in axle shaft to pull it out and bring large diameter
(2) of circlip at right as shown.

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Steering Knuckle / Wheel Spindle
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
3) Disconnect spindle vacuum hoses (1) from wheel spindle (for
4WD).
4) Remove disc dust cover (1) and wheel spindle (2).
5) Remove tie rod end (and drag rod end) nut(s) and discon-
nect tie rod end (and drag rod end) (2) from steering knuckle
(1) with special tool.
Special tool
(A) : 09913-65210
6) Remove knuckle seal cover bolts. Then remove knuckle seal
cover (1), knuckle seal and knuckle seal retainer from
knuckle. CAUTION:
Give match mark to each spindle vacuum hoses before
removing hose.

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INSTALLATION
1) Set knuckle seal cover (2), knuckle seal (4) and knuckle seal
retainer (5) on front axle housing (6).
2) Apply grease within the knuckle (1). Amount of grease to be
applied within the knuckle (1) is approximately 100 g (for
4WD).
“A” : Grease 99000-25030
3) Apply grease to kingpin bearings (3) and install them to front
axle housing (6).
“A” : Grease 99000-25030
4) Apply sealant to indicated part of kingpin (1).
“A” : Sealant 99000-31090
5) Install steering knuckle (1) and king pins (2) and tighten king-
pin bolts to specified torque.
Tightening torque
Kingpin bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
6) Apply grease to all around of knuckle seal lip.
“A” : Grease 99000-25010
7) Install knuckle seal retainer (1), knuckle seal (2) and knuckle
seal cover (3), tighten bolts to specified torque.
Tightening torque
Knuckle seal cover bolts
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) NOTE:
When reusing bearing (3), install bearing (3) with sealing
at the top.
NOTE:
Install knuckle seal cover (3) and knuckle seal retainer (1)
so that their split section comes at the top as shown in
figure.
4. Steering knuckle 5. Split part

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14) Blow air into pipes at the top and the front of wheel spindle
and check that it comes out of the hole as shown in figure
(for 4WD).
15) Connect spindle vacuum hoses to wheel spindle (for 4WD).
16) Connect tie rod and drag rod to steering knuckle, refer to
“Tie rod and Drag Rod” in Section 3B.
17) Install wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
18) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
19) Lower hoist.
Front Axle Shaft / Oil Seal / Kingpin Bearing
Outer Race
REMOVAL
1) Hoist vehicle.
2) Drain differential gear oil from front axle housing by loosing
drain plug (for 4WD).
3) Remove steering knuckle. For details, refer to “Steering
Knuckle / Wheel Spindle” in this section.
4) Draw out axle shaft (2).CAUTION:
As this hole is a part of the passage of the vacuum that
activates the air locking hub, if it is clogged with grease,
the air locking hub cannot be locked or unlocked.
Therefore, be careful not to apply too much grease to
avoid clogging the vacuum passage.
1. Front axle housing

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5) Remove oil seal (1) from axle housing (for 4WD).
6) Drain out kingpin bearing outer race (1) from front axle hous-
ing (2).
INSTALLATION
1) Install kingpin bearing outer race (1) to front axle housing by
using special tools.
Special tool
(A) : 09944-68510
(B) : 09924-74510
2) Press-fit oil seal (1) until it becomes flush with inner surface
of front axle housing (2) by using special tool.
Special tool
(A) : 09951-76010
3) Apply grease to oil seal lip.
“A” : Grease 99000-25010
3. Body center

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4) Install axle shaft (2) to front axle housing (1) (for 4WD).
5) Install knuckle to front axle housing. For details, refer to
“Steering Knuckle / Wheel Spindle” in this section.
6) Refill front axle (differential) housing with new specified gear
oil (for 4WD). Refer to “Maintenance Service” in Section 7E
for refill.
7) After servicing, check that no oil leakage exists.
Steering Knuckle Seal
REMOVAL
1) Hoist vehicle.
2) Remove knuckle seal cover bolts and seal cover (1).
3) Cut oil seal in place with scissors or knife, and take it off.
INSTALLATION
1) Cut replacement oil seal at one place with scissors or a
knife.

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Leading Arm / Bushing
REMOVAL
1) Hoist vehicle.
2) Remove air locking hub vacuum pipe clamp bolts (2) (for
4WD).
3) Support front axle housing by using floor jack.
4) Remove shock absorber lower mounting bolt, refer to “Front
Shock Absorber” in this section.
5) Remove mounting bolts and leading arm (1).
6) Remove bushings by using hydraulic press and special
tools.
Special tool
(A) : 09924-74510
(B) : 09951-16030
(C) : 09951-26010
1. Leading arm (right side)

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INSTALLATION
1) Install bushings (1) by using hydraulic press and special
tools, noting the following point.
Install bushings (1) so that either face of bushing are aligned
with housing edge of leading arm (2), also the length
between the aligned side end of bushing and leading arm (2)
are within specification below.
Special tool
(A) : 09913-85210
(B) : 09951-26010
Specification for leading arm bushing protrusion
“a” : 8.5 – 10.5 mm (0.33 – 0.41 in.)
“b” : 6.0 – 9.0 mm (0.24 – 0.35 in.)
2) Install leading arm (1) to vehicle body and axle housing,
referring to figure for proper installing direction of bolts.
Nuts should not be tightened.
3) Install shock absorber lower mounting bolt, refer to “Front
Shock Absorber” in this section.
4) Install air locking hub vacuum pipe clamp bolts and tighten
them to specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
5) Lower hoist and with vehicle in non-loaded condition, tighten
nuts of leading arm to specified torque.
Tightening torque
Leading arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
2. Vacuum hose
3. Body outside
[A] : Front
[B] : Rear