cent SUZUKI SWIFT 2006 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-5
8) Disconnect front suspension control arm ball joint
stud from steering knuckle.
9) Pull out drive shaft joint as follows. • For differential sideUsing tire lever (1), pull out drive shaft joint (2) so
as to release snap ring fitting of joint spline at
differential side.
• For center shaft side Using plastic hammer (3), drive out drive shaft
joint (2) so as to release snap ring fitting of joint
spline at center shaft.
10) Remove drive shaft assembly. 11) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from
differential side gear. Installation
CAUTION!
• Be careful not to damage oil seals and
boots when 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.

Install drive shaft assemb ly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as sp ecified referring to “A/T
Fluid Change in Section 5A” or “Manual Transaxle Oil
Change in Section 5B”.
• Check toe setting referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B” and adjust
as required.
[A]: Differential side
[B]: Center shaft side
I6RS0C310006-01
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2
1I2RH01310007-01

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
I3RH0A311004-01
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
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I4RS0B310003-01

Downloaded from www.Manualslib.com manuals search engine 3A-10 Drive Shaft / Axle:
11) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
12) Insert 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 housing end and small boot band)
Left side drive shaft “a”: 153.9 mm (6.05 in.)
Right side drive shaft “b”: 178.0 mm (7.00 in.)
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.

13) Place differential side (or center shaft side) boot new big band (3) and new small band (4) onto boot
putting band outer end (1) against forward rotation
(2) as shown in figure. 14) Fasten differential side (or center shaft side) boot
band.
• For differential side (or center shaft side) boot big band (1) and small band (5).
Fasten band by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I4RS0B310004-01
I5JB0A311006-01
(A)
1 4
2 3
(A)
5 4
2 3
I6RS0B310005-02

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 Drive Shaft / Axle: 3A-13
18) Place differential side boot (or center shaft side) new
big band (3) and new small band (4) onto boot
putting band outer end (1) against forward rotation
(2) as shown in figure.
19) Fasten differential side (or center shaft side) boot band.
• For differential side (or center shaft side) boot big band
Fasten band (1) by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
• For differential side (or center shaft side) boot small band
Fasten band (5) using special tool as shown in
figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(B): 09943–57010
I5JB0A311006-01
(A)
1 4
2 3
(B)
5 “a”
I5RS0B310013-01

Downloaded from www.Manualslib.com manuals search engine 3A-14 Drive Shaft / Axle:
Center Shaft and Center Bearing Support
Disassembly and Reassembly
S7RS0B3106005
Disassembly1) Remove snap ring and O-ring (M/T model) from center shaft.
2) Using hydraulic press (1), draw out center shaft (2) from center bearing.
3) Remove center bearing from bearing support as follows.
A/T model
a) Remove oil seals from center bearing support (3).
b) Remove bearing support circlip (1) using snap ring pliers (2) and then remove center bearing
from center bearing support.
M/T model
a) Remove bearing support circlip (1) using snap ring pliers (2) and then remove center bearing
from center bearing support.
Reassembly
Assemble center shaft by reversing disassembly
procedure and noting the following points.
• When installing bearing support circlip (1), make sure
that if fits in circlip groove in center bearing support (2)
securely as shown. • For A/T model, when installing
left oil seal (1) and right
oil seal (2) using special tool, use care so that oil seals
in proper direction and position as shown in figure.
Special tool
: 09925–15410
Distance
“a”: 7 – 8 mm (0.28 – 0.31 in.)
“b”: 0 – 1 mm (0 – 0.04 in.)
• For A/T model, be sure to apply grease to oil seal lip and bearing side space indicated in figure.
“A”: Grease 99000–25011 (SUZUKI Super Grease
A)
• Press-fit center shaft (1) from left oil seal (2) or circlip
(3) side.
• For M/T model, apply grease to O-ring and then install O-ring to center shaft.
I3RM0A310012-01
I6RS0B310006-03
[A]: A/T model [B]: M/T model
[A]: A/T model [B]: M/T model
I6RS0C310007-01
12
“A” “A”
“a” “b”
I4RS0A310014-01
I6RS0C310008-02

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-7
Repair Instructions
Brake Pedal ComponentsS7RS0B4106019
CAUTION!
Never disassemble brake pedalassembly.
Disassemble will spoil its originalfunction. If
faulty condition is found, replaceit with new
one.

Brake Pedal Free Height InspectionS7RS0B4106001
1) Check brake pedal free height. If it is not within specification, check and ad just following item 2) and
6).
Brake pedal free height “a” from carpet
130 – 150 mm (5.1 – 5.9 in.) 2) Check measurement between booster mounting
surface and center of clevis pin hole. When booster
push rod clevis has been reinstalled, it is important
that the measurement is adj usted (refer to “Brake
Booster Inspection and Adjustment”).
3) Check stop light switch position . Adjust it if it is out of
specification.
4) Check pedal for dent.
5) Check brake booster for installation.
6) Check brake booster push rod for length.
Brake Pedal Play InspectionS7RS0B4106002
Pedal play should be within the following specification. If
out of specification, check stop light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and booster clevis pin
installation for looseness and replace if defective.
Brake pedal play
“a”
: 1 – 8 mm (0.04 – 0.31 in.)
1. Brake pedal : 13 N⋅m (1,3 kgf-m, 9.5 lb-ft)
2. Brake pedal bracket
(a) 1
2
(a)
I7RS0B410002-01
I6RS0C410004-02
“a”I3RH0A410010-01