ball joint SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 0B-9 Maintenance and Lubrication:
Suspension System InspectionS6RW0D0206023
• Inspect front struts and rear shock absorbers for
evidence of oil leakage, dents or any other damage on
sleeves; and inspect anchor ends for deterioration.
Replace defective parts, if any.
• Check front and rear suspension systems for
damaged, loose or missing parts; also for parts
showing signs of wear or lack of lubrication.
Repair or replace defective parts, if any.
• Check front suspension arm ball joint stud dust seals
for leakage, detachment, tear or any other damage.
Replace defective boot, if any.
Steering System InspectionS6RW0D0206024
1) Check steering wheel for play and rattle, holding
vehicle straight on ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.1 in.)2) Check bolts and nuts for tightness and retighten
them as necessary. Repair or replace defective
parts, if any.
3) Check steering linkage for looseness and damage.
Repair or replace defective parts, if any.
4) Check boots (1) and (2) of steering linkage and
steering gear case for damage (leak, detachment,
tear, etc.). If damage is found, replace defective boot
with new one.
If any dent is found on steering gear case boots,
correct it to original shape by turning steering wheel
to the right or left as far as it stops and holding it for a
few seconds.
5) Check universal joints (3) of steering shaft for rattle
and damage. If rattle or damage is found, replace
defective part with a new one.
6) Check that steering wheel can be turned fully to the
right and left. Repair or replace defective parts, if
any.
7) If equipped with power steering system, check also,
in addition to check items, that steering wheel can be
turned fully to the right and left more lightly when
engine is running at idle speed than when it is
stopped. Repair, if found faulty.
8) Check wheel alignment referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
Drive Shaft (Axle) Boots InspectionS6RW0D0206025
Check drive shaft boots (wheel side and differential side)
for leaks, detachment, tear or other damage.
Replace defective parts as necessary.
I4RS0A020011-01
I4RS0A020012-01
I2RH01020026-01
2
3
2
1
1
I4RS0B020007-01
I2RH01310001-01

Downloaded from www.Manualslib.com manuals search engine Suspension General Diagnosis: 2A-1
Suspension
Suspension General Diagnosis
Diagnostic Information and Procedures
Suspension, Wheels and Tires Symptom DiagnosisS6RW0D2104001
Condition Possible cause Correction / Reference Item
Vehicle pulls (Leads)Mismatched or uneven tiresReplace tires.
Tires not adequately inflatedAdjust tire pressure.
Broken or sagging coil springsReplace coil springs.
Radial tire lateral forceReplace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Brake dragging in one road wheelRepair brake.
Loose, bent or broken front or rear
suspension partsTighten or replace related suspension parts.
Abnormal or excessive
tire wearSagging or broken coil springReplace coil spring.
Tire out of balanceAdjust balance or replace tire.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Faulty strut (shock absorber)Replace strut (shock absorber).
Hard drivingReplace tires.
Overloaded vehicleReplace tires.
Not rotated tiresReplace or rotate tires.
Worn or loose wheel bearingReplace wheel bearing.
Wobbly wheel or tireReplace wheel or tire.
Tires not adequately inflatedAdjust tire pressure.
Front suspension frame and/or
suspension control arm are transformedCheck and replace.
Wheel trampBlister or bump on tireReplace tire.
Improper strut (shock absorber) actionReplace strut (shock absorber).
Shimmy, shake or
vibrationTire or wheel out of balanceBalance wheel or replace tire and/or wheel.
Loosen wheel bearingsReplace wheel bearings.
Worn tie-rod endsReplace tie-rod ends.
Worn lower ball jointsReplace suspension control arm.
Excessive wheel runoutRepair or replace wheel and/or tire.
Blister or bump on tireReplace tire.
Excessively loaded radial runout of tire /
wheel assemblyReplace tire or wheel.
Disturbed wheel alignmentCheck and adjust wheel alignment.
Loose or worn steering linkageTighten or replace steering linkage.
Abnormal noise, front endWorn, sticky or loose tie-rod ends, lower
ball joints, tie-rod inside ball joints or
drive shaft jointsReplace tie-rod end, suspension arm, tie-rod
or drive shaft joint.
Damaged struts or mountingsRepair or replace struts or mountings.
Worn suspension arm bushingsReplace suspension arm bushings.
Loose stabilizer barTighten bolts or nuts and/or replace bushes.
Loose wheel boltsTighten wheel bolts.
Loose suspension bolts or nutsTighten suspension bolts or nuts.
Broken or damaged wheel bearingsReplace wheel bearings.
Broken suspension springsReplace suspension springs.
Worn strut bearingsReplace strut bearing.
Malfunction of Power Steering SystemCheck and correct malfunction.
Low or uneven trim height
NOTE
See NOTE *1.

Broken or sagging coil springsReplace coil springs.
Over loadedCheck loading.
Incorrect coil springsReplace coil spring.
Tires not adequately inflatedAdjust tire pressure.
Ride too softFaulty strut (shock absorber)Replace strut (shock absorber).
Suspension bottomsOverloadedCheck loading.
Faulty strut (shock absorber)Replace strut (shock absorber).
Incorrect, broken or sagging coil springsReplace coil spring.

Downloaded from www.Manualslib.com manuals search engine 2A-2 Suspension General Diagnosis:
NOTE
*1: Right-to-left trim height (“H”) difference should be within 15 mm (0.6 in.) with curb weight. (same
with rear side.)

Body leans or sways in
cornersLoose stabilizer barTighten stabilizer bar bolts or nuts, or replace
bushes.
Faulty strut (shock absorber) or
mountingReplace strut (shock absorber) or tighten
mounting.
Broken or sagging coil springsReplace coil springs.
OverloadedCheck loading.
Cupped tiresFront struts defectiveReplace struts.
Worn wheel bearingsReplace wheel bearings.
Excessive tire or wheel run-outReplace tire and/or wheel.
Worn ball jointsReplace suspension control arm.
Tire out of balanceAdjust tire balance. Condition Possible cause Correction / Reference Item
“H”
I2RH01210001-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-2
Front Wheel Alignment ConstructionS6RW0D2201002
Among factors for front wheel alignment, only toe setting
can be adjusted. Camber and caster are not adjustable.
Therefore, should camber or caster be out of
specification due to the damage caused by hazardous
road conditions or collision, whether the damage is in
body or in suspension should be determined and
damaged body should be repaired or damaged
suspension should be replaced.
Preliminary Checks Prior to Adjustment Front Wheel
Alignment
Steering and vibration complaints are not always the
result of improper wheel alignment. An additional item to
be checked is the possibility of tire lead due to worn or
improperly manufactured tires. “Lead” is the vehicle
deviation from a straight path on a level road without
hand pressure on the steering wheel. Refer to “Radial
Tire Lead / Pull Description in Section 2D” in order to
determine if the vehicle has a tire lead problem. Before
making any adjustment affecting wheel alignment, the
following checks and inspections should be made to
ensure correctness of alignment readings and alignment
adjustments:• Check all tires for proper inflation pressures and
approximately the same tread wear.
• Check for loose of ball joints. Check tie-rod ends; if
excessive looseness is noted, it must be corrected
before adjusting.
• Check for run-out of wheels and tires.
• Check vehicle trim heights; if it is out of limit and a
correction is needed, it must be done before adjusting
toe.
• Check for loose of suspension control arms.
• Check for loose or missing stabilizer bar attachments.
• Consideration must be given to excess loads, such as
tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment
checks.
• Consider condition of equipment being used to check
alignment and follow manufacturer’s instructions.
• Regardless of equipment used to check alignment,
vehicle must be placed on a level surface.
NOTE
To prevent possible incorrect reading of toe,
camber or caster, vehicle front and rear end
must be moved up and down a few times
before inspection.

Repair Instructions
Front Wheel Alignment Inspection and
Adjustment
S6RW0D2206001
Toe Inspection and Adjustment
Preparation for toe inspection and adjustment.
• Place vehicle in unloaded state on level surface.
• Set steering wheel in straight state.
• Check that inflation pressure of each tire is adjusted
properly and wheel is free from deflection.
• Check that each suspension part is free from bend,
dent, wear or damage in any other form.
• Check that ground clearance at the right and left is
just about the same.Inspection
Measure toe with toe-in gauge (1).
Toe should be within following specifications.
If toe is out of the specification, adjust toe properly.
To e
IN 1.0 ± 1.0 mm (0.0394 ± 0.0394 in.)
I2RH01220062-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-10
6) Pull out wheel hub (1) with special tools.
Special tool
(A): 09943–17912
(B): 09942–15511
CAUTION!
When wheel hub is removed, replace wheel
bearing with new one.

7) Disconnect tie-rod end (1) from steering knuckle (2)
with puller (3).
8) Remove wheel speed sensor (1) from knuckle.9) Loosen strut bracket nuts (1).
10) Remove ball joint bolt (4) and washer (3).
11) Remove strut bracket bolts (5) from strut bracket and
then steering knuckle (2).
12) Uncaulk and remove dust cover (1).
13) Remove circlip from knuckle.
14) Using hydraulic press (1) and special tool, remove
wheel bearing.
Special tool
(A): 09913–75510
(B): 09943–37910
I2RH01220028-01
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2
3
1
I4RS0A220017-01
1
I5RW0A220013-01
F: Vehicle front
F
5
21
3
4
I7RW01220004-01
I2RH01220032-01
I5RW0A220014-01

Downloaded from www.Manualslib.com manuals search engine 2B-13 Front Suspension:
9) Install ball joint bolt (1), washer (2), strut bracket
bolts (4) and new nuts (3) from the direction shown
in figure.
10) Tighten suspension arm ball joint bolt (2) to specified
torque.
Tightening torque
Suspension arm ball joint bolt (a): 60 N·m (6.0
kgf-m, 43.5 lb-ft)
11) Tighten new strut bracket nuts (3) to specified
torque.
Tightening torque
Strut bracket nut (b): 140 N·m (14.0 kgf-m, 101.5
lb-ft)
CAUTION!
Never reuse the removed strut bracket nut.

12) Install wheel speed sensor (1).
Tightening torque
Wheel speed sensor mounting bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)13) Connect tie-rod end (1) to steering knuckle (2),
tighten new nut (3) to specified torque.
Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
14) Install brake disk (2) and brake caliper (3).
15) Tighten caliper carrier bolt to specified torque.
Tightening torque
Caliper carrier bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
16) Depress foot brake pedal and hold it there.
Tighten new drive shaft nut (1) to specified torque.
Tightening torque
Drive shaft nut (a): 200 N·m (20.0 kgf-m, 145.0
lb-ft)
CAUTION!
Never reuse drive shaft nut (1).

17) Caulk drive shaft nut (1) as shown.
CAUTION!
Be careful not to damage the drive shaft nut
while caulking it. If it is damaged, replace it
with new one.

18) Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
19) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
F: Vehicle front
F
4
3, (b)
2
1, (a)
I7RW01220009-01
1(a)
I5RW0A220017-01
1
3, (a)
2I4RS0B220007-01
I7RW01220013-02

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-16
Assembly
1) Front bushing
Press-fit front bushing (1) by using special tools and
press (2).
Special tool
(A): 09943–76310
(B): 09913–75821
CAUTION!
Be sure to use new bushing.

NOTE
• Before installing bushing, apply soap
water on its circumference to facilitate
bushing installation.

2) Press-fit bushing (1) so that dimensions “A” and “B”
in figure become equal.
Suspension Control Arm / Steering Knuckle
Check
S6RW0D2206011
Inspect for cracks, deformation or damage.
If defective, replace.
Suspension Control Arm Bushing CheckS6RW0D2206012
Inspect for damage, wear or deterioration.
If defective, replace.
Suspension Control Arm Joint CheckS6RW0D2206013
• Check smooth rotation of ball stud.
• Check damages of ball stud.
• Check damages of dust cover.
NOTE
Suspension control arm and arm joint cannot
be separated.

If there is any damage to either parts, control arm must
be replaced as a complete unit.
12
(A) (B)
I4RS0B220021-01
I4RS0A220033-01
I4RS0B220022-01
I4RS0B220023-01

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-20
12) Install exhaust No.1, No.2 and center pipe referring
to “Exhaust System Components in Section 1K”.
13) Install wheel and tighten nut to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Install air cleaner assembly referring to “Air Cleaner
Assembly Removal and Installation in Section 1D”.
15) Install hood referring to “Hood Removal and
Installation in Section 9J”.
16) Lower hoist and vehicle in unloaded condition,
tighten suspension control arm bolts to specified
torque.
Tightening torque
Suspension control arm bolt: 95 N·m (9.5 kgf-m,
69.0 lb-ft)
17) Connect negative (–) cable at battery.
18) Confirm front wheel alignment referring to “Front
Wheel Alignment Inspection and Adjustment”.
Front Suspension Frame CheckS6RW0D2206017
Inspect for cracks, deformation or damage.
If defective, replace.
Front Stabilizer Bar, Bushing and/or Joint
Check
S6RW0D2206018
Stabilizer Bar
Inspect for damage or deformation.
If defective, replace.Stabilizer Bushing
Inspect for damage, wear or deterioration.
If defective, replace.
Stabilizer Joint
1) Check for smooth rotation.
2) Check damages of ball stud.
3) Check damages of dust cover.
NOTE
Stabilizer joint (1) cannot be disassembled.

If there is any damage to either parts, stabilizer joint
must be replaced as a complete unit.
Front Suspension Fasteners CheckS6RW0D2206019
Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque,
referring to “Front Suspension Construction”.
I5RW0A220034-01
I5RW0A220035-01
I5RW0A220036-01
1
I4RH01220007-01

Downloaded from www.Manualslib.com manuals search engine 2B-21 Front Suspension:
Specifications
Tightening Torque SpecificationsS6RW0D2207001
NOTE
The specified tightening torque is also described in the following.
“Front Suspension Construction”
“Front Strut Assembly Components”
“Front Wheel Hub and Steering Knuckle Components”
“Front Suspension Frame, Stabilizer Bar and/or Bushing Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Tie-rod end lock nut 45 4.5 32.5)
Strut bracket nut 140 14.0 101.5) / )
Brake hose mounting bolt 26 2.6 19.0)
Stabilizer joint nut 50 5.0 36.5) / )
Strut nut 50 5.0 36.5)
Wheel nut 85 8.5 61.5) / ) / ) / ) / )
Strut support lower nut 55 5.5 40.0)
Suspension arm ball joint bolt 60 6.0 43.5)
Wheel speed sensor mounting bolt 11 1.1 8.0)
Tie-rod end nut 45 4.5 32.5)
Caliper carrier bolt 85 8.5 61.5)
Drive shaft nut 200 20.0 145.0)
Suspension control arm bolt 95 9.5 69.0) / )
Stabilizer bar mounting bracket bolt Tighten 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) to
specified procedure)
Front suspension frame mounting bolt 150 15.0 108.5)

Downloaded from www.Manualslib.com manuals search engine 3A-1 Drive Shaft / Axle: Front
Driveline / Axle
Drive Shaft / Axle
Front
General Description
Front Drive Shaft ConstructionS6RW0D3111001
A constant velocity ball joint is used on the wheel side of both right and left side drive shaft assemblies. For A/T
vehicle, a tripod type constant velocity joint is used on the differential side and center shaft side. For M/T vehicle, a
double offset type constant velocity joint (DOJ) is used on the differential side and center shaft side. The drive shaft
can slide through the tripod joint or the double offset joint (DOJ) in the extension/contraction direction.
Component Location
Front Drive Shaft Assembly Components LocationS6RW0D3113001
I6RW0D311001-01
1. To transaxle 7. Wheel nut : 200 N⋅m (20.0 kgf-m, 145.0 lb-ft)
2. Drive shaft assembly 8. Center shaft assembly (if equipped) : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
3. Tie-rod end 9. Center bearing support bolts (if equipped) : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
4. Tie-rod end nut 10. Washer : Do not reuse.
5. Ball stud bolt : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)
6. Drive shaft nut
: After tightening nut to specified torque,
caulk nut securely.:60 N⋅m (6.0 kgf-m, 43.5 lb-ft)