differential SUZUKI SWIFT 2000 1.G RG413 Service Owner's Manual

FRONT DRIVE SHAFT 4A-7
4) Draw away cage (1) by using bearing puller (2), and remove
boot (3) from shaft.
5) Remove boot band, then pull out differential side boot from
shaft.
6) Pull out damper through shaft. (if equipped)
7) Undo boot bands of wheel side joint boot, then pull out boot
through shaft.
For Center Shaft and Center Bearing Support
1) Remove right side oil seal from center bearing support (1).
2) Remove circlip by using special tool.
Special tool
(A) : 09900-06108
3) Using hydraulic press (1), draw out center shaft (2) from cen-
ter bearing.
4) Remove left side oil seal from center bearing support (3).
CAUTION:
Do not disassemble wheel side joint. If any malcondition
is found in any joint, replace it as assembly.

4A-8 FRONT DRIVE SHAFT
5) Remove circlip (1) by using flat end rod or the like.
6) Remove center bearing (2) from center bearing support.
ASSEMBLY
For Tripod Joint Type Drive Shaft
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, and boots (3)
are cleaned with cloth if they are to be reused.
“A” : Black grease (about 60 - 80 g/2.1 - 2.8 oz)
“B” : Orange grease (about 85 - 105 g/3.0 - 3.7 oz)
1) Wash disassembled parts (except boots). After washing, dry
parts completely by blowing air.
2) Clean boots with cloth. DO NOT wash boots in degreaser,
such as gasoline or kerosene, etc. Washing in degreaser
causes deterioration of boot.
3) Apply grease to wheel side joint. Use specified grease in
tube in wheel side boot set.
4) Install wheel side boot on shaft.
CAUTION:
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 followings for identification of the grease.
[A] : Wheel side
[B] : Differential side

FRONT DRIVE SHAFT 4A-9
5) Fill up boot inside with specified grease and then fasten boot
with bands (1).
6) Install dynamic damper (1) on drive shaft according to
dimension specified below.
Drive shaft dynamic damper installing position
“a” : 347 - 353 mm (13.7 - 13.9 in.)
7) Set new differential side small band and differential side boot
(1) on shaft temporarily.
Apply grease to tripod joint (2). Use specified grease in tube
included in spare parts.
8) Install tripod joint spider (3) on shaft, facing its chamfered
spline inward (wheel side), then fasten it with snap ring (4).
Special tool
(A) : 09900-06107
9) Apply grease to inside of outer race (1), then install housing,
joint it with boot and fit boot 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
becomes the same as atmospheric pressure. CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.

4A-10 FRONT DRIVE SHAFT
10) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measured dimensions become as
indicated below.
Drive shaft boot fixing position
“a” : 155.5 mm (6.12 in.) for M/T vehicle
“b” : 189.3 mm (7.45 in.) for A/T vehicle
CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots and tripod joint except its housing.
Degreasing of those parts with cloth is allowed.
[A] : Wheel side
[B] : Differential side
CAUTION:
Bend 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.

FRONT DRIVE SHAFT 4A-11
For DOJ Type Drive Shaft
Judging from abnormality noted before disassembly and what is
found though visual check of component parts after disassembly,
prepare replacing parts and proceed to reassembly.
Make sure that wheel side joint assembly (1) and DOJ housing
(2) are washed thoroughly and air dried, and boots (3) are
cleaned with cloth if they are to be reused.
“A” : Black grease (about 60 - 80 g/2.1 - 2.8 oz)
“B” : Black grease (rather light than “A”)
(about 70 - 90 g/2.5 - 3.2 oz)
1) Wash disassembled parts (except boots). After washing. dry
parts completely by blowing air.
2) Clean boots with cloth. Do not wash boots in degreaser,
such as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.
3) Apply grease to wheel side joint. Use specified grease in
tube included in wheel side boot set.
4) Install wheel side boot on shaft, fill up boot inside with
grease and then fasten boot with bands (1).
5) Install dynamic damper (1) on left side drive shaft according
to dimension specified below. (For A/T model of 2WD vehi-
cle)
Dynamic damper installing position
“a” : 151 - 157 mm (5.9 - 6.2 in.)
6) Set new differential side small bend and differential side boot
on shaft temporarily. CAUTION:
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.
[A] : Wheel side
[B] : Differential side
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.

FRONT DRIVE SHAFT 4A-13
12) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measurements become as indicated
below.
Drive shaft boot fixing position
“d” : 157.8 mm (6.21 in.) for left side
“e” : 192.9 mm (7.59 in.) foe right side
For Center Shaft and Center Bearing Support
Install center shaft by reversing removal procedure and noting fol-
lowing points
When installing bearing support circlip (1), make sure that if
fits in circlip groove in center bearing support (2) securely as
shown.
When installing left oil seal (1), use care so that oil seal in
proper direction as shown figure.
Be sure to apply grease to oil seal lip and bearing side space
indicated in figure.
“A” : Grease 99000-25010
After press-fit center shaft (2) from left oil seal side, install
circlip to groove of center shaft securely. CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with
cloth is allowed.
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.
[A] : Differential side

4A-14 FRONT DRIVE SHAFT
When installing right oil seal (1), use care so that oil seal in
proper direction as shown figure.
Be sure apply grease to oil seal lip and bearing side space
indicated in figure.
“A” : Grease 99000-25010
INSTALLATION
Install drive shaft assembly by reversing removal procedure and
noting following points.
Clean front wheel bearing oil seal (1) and then apply grease.
Replace it if required.
“A” : Grease 99000-25010
CAUTION:
To avoid excessive expansion of boot and consequen-
tial disconnection of joint in boot, do not pull differen-
tial side joint housing.
Protect oil seals and boots from any damage, prevent-
ing them from unnecessary contact while installing
drive shaft.
Do not hit joint boot with hammer. Inserting joint only
by hands is allowed.
Make sure that differential side joint is inserted fully
and its snap ring is seated as it was.

4B-2 PROPELLER SHAFTS
PROPELLER SHAFT JOINT CHECK
If universal joints are suspected of producing chattering or rattling
noise, inspect them for wear. Check to see if cross spider rattles
in yokes or if splines are worn down and replace defective propel-
ler shaft with new one.
Noise coming from universal joint can be easily distinguished
from other noises because rhythm of chattering or rattling is in
step with cruising speed. Noise is pronounced particularly on
standing start or in coasting condition (when braking effect of
engine is showing in the drive line).
ON-VEHICLE SERVICE
REMOVAL
1) Hoist vehicle.
2) Before removing propeller shaft, give match mark (1) on pro-
peller shaft and companion flange as shown. Also give
match mark (1) on propeller shaft No.2 and center support
flange of propeller shaft No.1.
3) Loosen propeller shaft bolt at front and rear end, and sepa-
rate propeller shaft from transfer and rear differential.
1. Propeller shaft No.1
2. Center support
3. Propeller shaft No.2
4. Forward
Tightening torque

6A1-70 ENGINE MECHANICAL (M13 ENGINE)
15) Remove exhaust No.1 pipe (1).
16) Disconnect right and left drive shaft joints from differential
gear referring to Section 4.
For engine and transmission removal, it is not necessary to
remove drive shafts from steering knuckle.
17) For 4WD vehicle, remove propeller shaft referring to Section
4B.
18) Remove generator referring to Section 6H.
19) Install lifting device.
20) Remove engine rear mounting bolts (1), engine left mounting
bracket nuts (2) and engine right mounting bolts (3).