Sas SUZUKI SX4 2006 1.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-10
For tripod joint type
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 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 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.7) Fasten boot bands (1) securely using special tool as
shown in figure.
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
Special tool
(A): 09943–57010
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Front 3A-12
15) Fasten differential side (or center shaft side) boot big
band (1) and small band (5) by drawing hooks (2)
with special tool and engage hooks (3) in slot and
window (4).
Special tool
(A): 09943–57021Center Shaft and Center Bearing Support
Disassembly and Reassembly (If Equipped)
S6RW0D3116005
Disassembly
1) Using hydraulic press (1), draw out center shaft (2)
from center bearing.
2) Remove oil seals from center bearing support (3).
3) Remove bearing support circlip (1) using snap ring
pliers (2).
4) Remove center bearing from center bearing support.
Reassembly
Install center shaft by reversing removal 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.
(A)
1
4
2
3
(A)
5
4
2
3
I4RS0B310008-02
I3RM0A310012-01
I7RW01311005-01
2
1
I5RW0A311006-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: Rear 3A-16
Rear Drive Shaft Assembly Removal and
Installation
S6RW0D3126002
Removal
1) Hoist vehicle and remove rear wheel.
2) Undo caulking of drive shaft nut (1) and then remove
drive shaft nut with pull up parking brake lever.
3) Remove rear drive shaft flange nuts (1), and then
remove rear drive shaft.
Installation
Install drive shaft assembly by reversing removal
procedure and noting the following points.
CAUTION!
• Protect boots from any damage,
preventing them from unnecessary contact
while installing drive shaft.
• Do not hit joint boot with hammer.
Inserting joint only by hands is allowed.

• Tighten each nuts to specified torque referring to
“Rear Drive Shaft Components”.
Rear Drive Shaft Disassembly and ReassemblyS6RW0D3126003
Disassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following point which is different
from the front drive shaft is described.
• Remove differential side boot big band and small
band as follows.
– For boot big band (and small band) without joint [A]:
Remove boot big band (and small band) by tapping
boot and band with plastic hammer. If it is hard to
remove boot big band (and small band), cut it using
a nipper or an iron saw with care not to damage
joint housing.
– For boot big band (and small band) with joint [B]:
Draw hooks of boot big band (and small band)
together and remove band.
1
I5RW0A230023-01
1
I5RW0A312006-02
I5RW0A312003-01

Downloaded from www.Manualslib.com manuals search engine 3A-17 Drive Shaft / Axle: Rear
Reassembly
Refer to “Front Drive Shaft Disassembly and
Reassembly” note the following points which is different
from the front drive shaft is described.
• Apply grease to each joint.
Grease color
Wheel side: Black
Differential side: Dark gray
Amount
Wheel side: 50 – 70 g (1.8 – 2.5 oz)
Differential side: 70 – 90 g (2.5 – 3.2 oz)
• Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
• Fit differential side boot as follows.
– Fit boot (1) to grooves of shaft and housing (2)
adjust length to specification below.
– 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
center)
Left side and right side drive shafts “a”: 142.5
mm (5.61 in.)• Fasten differential side boot band as follows.
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.

– Place differential side boot new big band (3) and
new small band onto boot putting band outer end
(1) against forward rotation (2) as shown in figure.
– Fasten differential side boot new big band (1) and
new small band by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
(A)
1
I5RS0B310009-01
“a”
2
1I5RW0A312007-01
I5RW0A312004-01
(A)
1
4
2
3
I5RW0A312005-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-14
Rear Differential Symptom DiagnosisS6RW0D3204011
4WD Control Symptom DiagnosisS6RW0D3204012
Diagnose 4WD system after performing the following inspections.
• Perform 4WD control system check referring to “4WD Control System Check”. Condition Possible cause Correction / Reference Item
Gear noiseDeteriorated or water mixed lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
Inadequate or insufficient lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
Maladjusted backlash between drive
bevel pinion and gearAdjust as prescribed referring to “Rear
Differential Disassembly and Reassembly”.
Improper tooth contact in the mesh
between drive bevel pinion and gearAdjust or replace referring to “Rear Differential
Disassembly and Reassembly”.
Loose drive bevel gear securing boltsReplace or retighten referring to “Rear
Differential Disassembly and Reassembly”.
Damaged differential gear(s) or
differential pinion(s)Replace referring to “Rear Differential
Inspection”.
Bearing noise(Constant noise) Deteriorated or water
mixed lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
(Constant noise) Inadequate or
insufficient lubricantRepair and replenish referring to “Rear
Differential Oil Change”.
(Noise while coasting) Damaged
bearing(s) of drive bevel pinionReplace referring to “Rear Differential
Inspection”.
(Noise while turning) Damaged
differential side bearing(s) or axle
bearing(s)Replace referring to “Rear Differential
Inspection”.
Oil leakageClogged breather plugClean.
Worn or damaged oil sealReplace.
Excessive oilAdjust oil level referring to “Rear Differential Oil
Change”.
Loose differential carrier boltsReplace or retighten.
Condition Possible cause Correction / Reference Item
4WD system does not
operate2WD/4WD switch faultyCheck switch referring to “2WD/4WD Switch
Inspection”.
Coupling air temperature sensor faultyCheck coupling air temperature sensor
referring to “Coupling Air Temperature Sensor
Inspection”.
Coupling assembly faultyCheck coupling assembly referring to
“Coupling Assembly Inspection”.
Wiring or grounding faultyRepair as necessary.
4WD control module faultyCheck 4WD control module referring to
“Inspection of 4WD Control Module and Its
Circuits”.
MAF sensor faultyCheck MAF sensor and its circuit.
Accelerator pedal position (APP) sensor
faultyCheck accelerator pedal position (APP) sensor
and its circuit.
CKP sensor faultyCheck CKP sensor and its circuit.
Front and/or rear wheel speed sensor
faultyCheck front and/or rear wheel speed sensor
and its circuit.
Steering angle sensor faultyCheck steering angle sensor and its circuit.
ABS / ESP® control module faultyCheck ABS / ESP
® control module and its
circuit.
ECM faultyCheck ECM and its circuit.
NoiseDamaged or worn bearing(s)Refer to “Rear Differential Inspection”.

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-34
Front Mounting Arm and/or Rear Mounting
Bracket Assembly Removal and Installation
S6RW0D3206010
Remove and install front mounting arm and/or rear
mounting bracket after rear differential removed.
For tightening torque of each bolt and nut, refer to “Rear
Differential Mountings Components”.
Rear Mounting Bracket Assembly Disassembly
and Reassembly
S6RW0D3206011
Disassembly
Drive out mountings from rear mounting bracket using
special tool and hydraulic press.
Special tool
(A): 09913–70123
(B): 09951–26020
Reassembly
Press mountings in rear mounting bracket using special
tool and hydraulic press with caring its installation
position shown in figure.
Special tool
(A): 09913–85210
(B): 09951–26020
Rear Differential Dismounting and RemountingS6RW0D3206012
Dismounting
1) Lift up vehicle and drain oil from rear differential.
2) Remove propeller shaft referring to “Propeller Shaft
Assembly Removal and Installation in Section 3D”.
3) Remove rear drive shafts assembly referring to
“Rear Drive Shaft Assembly Removal and
Installation in Section 3A”.
4) Support rear differential (3) with transmission jack
(4).
5) Remove mounting arm bolts (2) and rear mounting
bolts (1), and then lower rear differential with rear
mounting bracket.
Remounting
Reverse dismounting procedure for remounting of rear
differential, noting the following points.
• Tighten each bolt to specified torque referring to “Rear
Differential Mountings Components”.
• Fill gear oil to rear differential referring to “Rear
Differential Oil Change”.
(B)
(A)
I5RW0A320023-02
(A)
(B)
I5RW0A320024-02
3
4 21
I5RW0A320025-01

Downloaded from www.Manualslib.com manuals search engine 3B-35 Differential:
Rear Differential ComponentsS6RW0D3206013
4 5
9
2
30
6
(a)13
12
(a)
3
A
3A
141617 2118
29
3A
1(b)
22
1217G
101217G
11
8OIL
15OIL
19 20OIL
23OIL
25OIL27OIL
27OIL
25OIL
19OIL18
26 28
OIL
26OIL23OIL
24OIL
(c)
14
7
I5RW0A320026-02
1. Flange nut 13. Differential cover bolt 25. Differential gear
2. Companion flange 14. Spacer 26. Spring washer
3. Oil seal
: Apply grease 99000-25010 to oil seal lip.15. Rear bearing 27. Thrust washer
4. Coupling front bearing 16. Shim 28. Pinion shaft
5. Coupling case
: Apply sealant 99000-31260 to mating surface of carrier and coupling
case.17. Bevel pinion 29. Pinion shaft pin
6. Coupling assembly
: Never disassemble.18. Shim 30. Coupling case bolt
7. Snap ring 19. Differential side bearing : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
8. Bevel pinion nut
: Tighten nut so as rotation torque of bevel pinion to be in specified value.20. Bevel gear : 125 N⋅m (12.5 kgf-m, 90.5 lb-ft)
9. Front bearing 21. Differential case : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft)
10. Differential carrier
: Apply sealant 99000-31260 to mating surface of carrier and rear cover.22. Bevel gear bolt : Do not reuse.
11. Coupling air temperature sensor 23. Pinion washer : Apply differential oil.
12. Differential cover 24. Pinion

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-36
Rear Differential Disassembly and ReassemblyS6RW0D3206014
Disassembly
1) Remove rear mounting bracket from rear differential
referring to “Front Mounting Arm and/or Rear
Mounting Bracket Assembly Removal and
Installation”.
2) Remove drive shaft flanges.
3) Separate coupling case from differential carrier using
special tool.
Special tool
: 09912–34510
4) Hold companion flange with special tool and then
remove flange nut.
Special tool
(A): 09930–40113
5) Remove companion flange (1) from pinion. Use
special tool if it is hard to remove.
Special tool
(A): 09913–651356) Remove coupling assembly (1) by using hydraulic
press.CAUTION!
Do not drop coupling assembly. If it is
dropped, replace it with a new one.

7) Disassemble coupling case as follows, if necessary.
a) Remove oil seal using special tool.
Special tool
(A): 09913–50121
b) Remove snap ring using snap ring pliers.
c) Remove bearing using special tool and hydraulic
press.
Special tool
(A): 09913–75830
(A)
I5RW0A320027-01
(A)
1
I5RW0A320028-01
1
I5RW0A320029-01
(A)
I5RW0A320030-01
(A)
I5RW0A320031-01

Downloaded from www.Manualslib.com manuals search engine 3B-37 Differential:
8) Remove oil seals from rear differential (1) using
special tool.
Special tool
(A): 09913–50121
9) Remove differential cover (1) using special tool, and
then take out differential assembly, outer race and
shim all at once.
Special tool
(A): 09912–34510
10) Pull out differential side bearings (1) using special
tools.
Special tool
(A): 09913–60910
(B): 09925–88210
11) Remove drive bevel gear (hypoid gear), differential
gears, differential pinions and pinion shaft as follows.
a) With aluminum plates (2) placed on vise first,
grip differential case with it and remove drive
bevel gear (hypoid gear) (3) by removing its bolts
(1).b) Drive out differential side pinion shaft pin with
special tool and hammer.
Special tool
(B): 09922–85811
c) Disassemble differential gears (2), pinions (3),
washers and shaft (4) in differential case (1).
12) Remove bevel pinion nut with special tool.
Special tool
(A): 09927–27910
13) Remove rear bearing (2) from drive bevel pinion (1)
by using bearing puller (3) and hydraulic press.
1(A)I5RW0A320032-01
(A)
1
I5RW0A320033-01
(A)
(B)
1
I5RW0A320034-02
1
3
2
I5RW0A320035-01
I5RW0A320036-01
(A)
I5RW0A320037-04
I3RH01322026-01

Downloaded from www.Manualslib.com manuals search engine Differential: 3B-38
14) Using a hammer and brass bar (1), drive out front
bearing outer race (2).
15) Using a hammer and brass bar (1), drive out rear
bearing outer race (2).
Reassembly
Judging from faulty conditions noted before disassembly
and what is found through visual check of bearing and
gear tooth etc. after disassembly, prepare replacing
parts and proceed to reassembly according to
procedures as described in the following.
CAUTION!
• Bevel gear and pinion must be replaced as
a set when either replacement becomes
necessary.
• When replacing taper roller bearing,
replace as inner race & outer race
assembly.

1) Press-fit bevel pinion bearing outer races to
differential carrier (1) by using special tools and
hydraulic press as shown in the figure.
Special tool
(A): 09913–85210
(B): 09913–75510
2) After applying differential oil to differential gears (4),
pinions (5), pinion shaft (3), side washers (1), spring
washers (7) and pinion washers (2), install them in
differential case (6).
For correct installing direction of side washers and
spring washers, refer to figure.
NOTE
Used left and right differential side washers
are not interchangeable.

3) Check pinion gear (1) for smooth rotation.
1
2
I5RW0A320038-01
1
2
I5RW0A320039-01
(B)(A)
1
I5RW0A320040-02
7 6
4
5
3
21
I5RW0A320041-01
I3RH01322031-01