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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 >> Installation Procedure
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Installation 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: Identifying New Small Seal Clamp & Outboard Seal
G04842828Courtesy of SUZUKI OF AMERICA CORP.
  1. Install the new small seal clamp (2) on the neck of the outboard seal (1). Do not clamp.
  2. Slide the outboard seal onto the wheel drive shaft bar and position the neck of the outboard seal in the seal groove on the bar. The largest groove below the sight groove on the wheel drive shaft bar is the seal groove seal (3).
    NOTE: Ensure that the seal clamp is properly positioned around the entire circumference of the seal.
    Fig 2: Measuring Clamp End Gap Dimension
    G04842829Courtesy of SUZUKI OF AMERICA CORP.
  3. Crimp the seal clamp using the J 35910.
  4. Measure the clamp end gap dimension. The gap should not exceed 2.15 mm (0.085 in).

    Specification 

    The gap should not exceed 2.15 mm (0.085 in)  .

    Fig 3: Installing Inner Race To Cage
    G04842830Courtesy of SUZUKI OF AMERICA CORP.
  5. Put a light coat of grease from the service kit on the bearing roller grooves of the inner race and outer race.
  6. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage.
    Fig 4: Holding Cage & Inner Race 90 Degrees To Center Line Of Outer Race & Align Cage Windows
    G04842831Courtesy of SUZUKI OF AMERICA CORP.
  7. Hold the cage and inner race 90 degrees to the center line of the outer race (1) and align the cage windows (3) with the lands of the outer race.
    NOTE: Be sure that the retaining ring side of the inner race faces the wheel drive shaft bar.
  8. Place the cage and the inner race into the outer race.
  9. Insert the first bearing roller, then tilt the cage to insert every other bearing roller.
  10. Repeat this process until all 6 bearing rollers are in place.
  11. Install the CV joint retaining ring to the wheel drive shaft bar.
  12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
    Fig 5: Installing Large Seal Retaining Clamp Over Seal & Close Using J 35910
    G04842832Courtesy of SUZUKI OF AMERICA CORP.
  13. Place a block of wood against the CV joint spindle and tap on the block of wood until the CV joint inner race engages the retaining ring.
  14. Slide the large diameter of the seal over the outside of the CV race and locate the lip of the seal in the housing groove.
  15. Install the large seal retaining clamp over the seal and close using the J 35910
  16. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.

    Specification 

    Dimension equals 1.9 mm (5/64 in)  .

  17. Remove the wheel drive shaft from the bench vise.
  18. Distribute the grease within the outer CV joint by rotating the joint in a circular motion four to five times.
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