Automatic Free Wheel Hub Modification (TS 5-09 10046)

Publication date: 1996-10-04
Reference number: TS 5-09 10046

AUTOMATIC FREE WHEEL HUB MODIFICATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 5-09 10046, Date of Issue: October 4, 1996

MODIFICATION OF AUTOMATIC FREE WHEEL HUB

Model(s): Jan. 96 Production & Later - Suzuki Sidekick, Sidekick Sport, X-90

Section: Steering, Brakes & Suspension

Bulletin No.: TS 5-09 10046

Date: October 4, 1996

CONDITION

Modification of automatic free wheel hub.

CAUSE

N/A.

CORRECTION

When replacing the automatic hub, please use the part number and repair procedures contained in this bulletin.

SERVICE INFORMATION

This bulletin is to inform you of the modification of the automatic free wheel hub assembly. When ordering or disassembling the automatic free wheel hub assembly, please use the part numbers and repair procedures contained in this bulletin.

VIN INFORMATION

Model	Effective Starting VIN
Sidekick	JS3TA01C_T4140043
JS3TD03V_T4100156
Sidekick Sport	JS3TD21V_T4108837
X-90	JS3LB11S_T4104479

PARTS INFORMATION

Part Name	Early Part No.	Late Part No.	Qty.
Auto Free Wheel Assembly	43810-60A10	43810-60A20	1
Auto Free Wheel Cover	43814-60A10	- -	1
Auto Free Wheel O-ring	43815-83000		1
NOTE: Interchangeability is Early - Late when replacing both right and left auto free wheel hubs at the same time.

FRONT SUSPENSION - 4WD MODEL

NOTE:

For the descriptions (items) not found in this section, refer to the same section of the Service Manual mentioned in Foreword of this manual.
All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. DO NOT use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or damage to the part may result.

FRONT FREE WHEELING HUB (IF EQUIPPED)

There are two types of the front free wheeling hub in this vehicle (if equipped). One is manual type and the other is automatic type.

As removal, installation and maintenance procedures vary between them, be sure to correct section applicable to each kind.

CAUTION:

Make sure that the same front free wheeling hub is installed for both right and left.
For vehicle equipped with manual free wheeling hub, both of the right and left wheeling hub knobs must be set to the same position (either FREE or LOCK). DON'T set one to "FREE" and the other to "LOCK" positions.
Never disassemble free wheeling hub assembly. Disassembly will spoil its original function.

MANUAL FREE WHEELING HUB

Refer to the same section of the Service Manual mentioned in Foreword of this manual for operation, installation and maintenance.

AUTOMATIC FREE WHEELING HUB

See Fig 1 .

REMOVAL

Set free wheeling hub to free condition. (Set transfer gear shift lever to 2H position, and move vehicle 2 m (6.5 ft) or more backward slowly.)
Hoist vehicle, if wheel (tire) removal is necessary.
Remove wheel (tire), if necessary.
Remove free wheeling hub (sub assembly and brake assembly) slowly. See Fig 2 .

INSTALLATION

Check O-ring for damage and clean mating surfaces of hubs.
Install free wheeling hub brake assembly to spindle aligning key of brake assembly with slot in spindle. See Fig 3 .
Install free wheeling hub sub assembly to spindle aligning the match marks of brake assembly and sub assembly. See Fig 4 .
CAUTION: Make sure that match marks are aligned. If they aren't, wire brake and release plate may interfere with each other causing spring to break.
Tighten hub bolts to specified torque. See Fig 5 . SPECIAL TOOL: (A): 09900-00414 (6 mm bit) (B): 09900-00411 (Socket) TIGHTENING TORQUE: (b): 33 N.m, 3.3 kg-m, (24 ft-lb).
Install front wheels and tighten wheel nuts to specified torque, if removed. See Fig 6 . TIGHTENING TORQUE: (c): 95 N.m, 9.5 kg-m, (69.0 ft-lb).
Dismount the vehicle from the lift, and be sure to carry out the operation check of free wheeling hub mentioned in the next item POST-ASSEMBLY CONFIRMATION .

POST-ASSEMBLY CONFIRMATION

Confirm automatic free wheeling hub for proper operation in the sequence described below: See Fig 7 .

Set transfer gear shift lever to 4H or 4L position, and move vehicle 2 m (6.5 ft) or more forward slowly.
Hoist vehicle and check that wheel (tire) rotation is transmitted to drive shaft (lock condition) when rotating right wheel clockwise (left wheel counterclockwise) by hand.
Dismount vehicle from lift.
Set transfer gear shift lever to 2H position, and move vehicle 2 m (6.5 ft) or more backward slowly.
Hoist vehicle and check that wheel (tire) rotation is not transmitted to drive shaft (free condition) when rotating right wheel clockwise (left wheel counterclockwise) by hand. See Fig 8 .
Check to ensure that free wheeling hub locks and unlocks properly by reversing vehicle moving directions described in steps 1 and 4. (It should lock when moving backward and unlock when moving forward.)

If any malfunction is found as to the confirmation in the above steps 1 through 6, reinstall or replace free wheeling hub assembly.

MAINTENANCE SERVICE

Confirm automatic free wheeling hub for proper operation periodically according to the procedure described previously in "Post-assembly confirmation" If automatic free wheeling hub shows any malfunction, replace it with new one.