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Home >> Suzuki >> 1987 >> Samurai Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 37 (Drive Shaft / Axle) >> Repair Instruction >> Front Wheel Drive Shaft Outer Joint and Seal Replacement >> Disassembly Procedure
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Disassembly Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Clamping Drive Axle Shaft In Soft Jawed Vice
G04842822Courtesy of SUZUKI OF AMERICA CORP.
  1. Clamp the drive axle shaft in a soft jawed vice.
    Fig 2: Disengaging Retaining Tabs Of Large Seal Clamp
    G04842823Courtesy of SUZUKI OF AMERICA CORP.
  2. Use a flat-bladed tool and disengage the retaining tabs of the large seal clamp.
  3. Discard the clamp.
  4. Remove the small seal clamp using side cutters and discard the clamp.
  5. Separate the constant velocity (CV) joint boot from the CV joint race at the large diameter.
  6. Slide the boot away from the joint along the wheel drive shaft bar.
  7. Wipe the excess grease from the face of the CV inner race.
    Fig 3: Removing CV Joint Outer Race From Wheel Drive Shaft Bar
    G04842824Courtesy of SUZUKI OF AMERICA CORP.
  8. Place a block of wood against the CV joint outer race and carefully tap on the CV joint to remove it from the wheel drive shaft bar.
  9. Remove the seal from the wheel drive shaft bar.
  10. Remove the CV joint retaining ring from the wheel drive shaft bar.
    Fig 4: Identifying CV Joint Inner Race
    G04842825Courtesy of SUZUKI OF AMERICA CORP.
  11. Place a brass drift against the CV joint inner race (1).
  12. Tap gently on the brass drift with a hammer in order to tilt the joint race.
  13. Remove the first bearing roller (2) when the CV race tilts.
  14. Repeating the steps above, tilt the CV joint inner race in the opposite direction to remove the opposing bearing roller.
  15. Repeat the process to remove all 6 of the bearing rollers.
    Fig 5: Pivoting CV Joint Cage & Inner Race 90 Degrees To Centerline Of Outer Race
    G04842826Courtesy of SUZUKI OF AMERICA CORP.
  16. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race.
  17. Lift out the cage (4) and the inner race.
    Fig 6: Removing Inner Race From Cage
    G04842827Courtesy of SUZUKI OF AMERICA CORP.
  18. Remove the inner race (1) from the cage (2) by rotating the inner race upward.
  19. Clean the following items thoroughly with a suitable solvent. Remove all traces of grease and contaminants.
    • The inner and outer race assemblies.
    • The CV joint cage.
    • The bearing rollers.
  20. Dry all the parts with compressed air.
  21. Inspect the CV joint assembly for the following:
    • Unusual wear
    • Cracks
    • Damage
  22. Replace any damaged parts.
  23. Clean the wheel drive shaft bar. Use a wire brush to remove any rust in the seal mounting grooves.
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