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Reassembly (DOJ)

WARNING: This page is about a different car, the 2004 Suzuki Aerio. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to the exploded view as needed during this procedure. See Figure .
CAUTION: To ensure full performance of joint, be sure to distinguish between 2 types of grease in repair set and apply specified amount to each. See Fig 1 .
  1. Wash disassembled parts. After wash, dry parts completely by blowing air.
  2. Apply grease to wheel side joint. Use specified grease in supplied in boot set.
    CAUTION: Bend each boot end against forward rotation (A).
    DO NOT squeeze or distort boot when fastening it with bands. Distorted boot may reduce its durability.
  3. Install wheel side boot on shaft, fill up boot inside with grease, and fasten boot with bands (1). See Fig 2 .
  4. Install damper (1) on LH drive shaft according to dimension. See Fig 3 .
  5. Set new differential side boot small band and differential boot on shaft temporarily.
  6. Drive in cage (1) by using a pipe (2). See Fig 4 .
  7. Install circlip (1) by using the snap ring pliers. See Figure .
  8. Apply grease to entire surface of cage. Use specified grease supplied in boot set.
    CAUTION: Position opening of snap ring "c" so that it will not be lined up with a ball.
  9. Insert cage in the joint housing (2) and fit snap ring (1) into groove of joint housing (2). See Fig 5 .
  10. Apply grease to inside of joint housing (1), and then fit boot (2) to joint housing. See Fig 6 . After fitting boot, insert screwdriver into boot on joint housing side and allow air to enter boot so that air pressure in boot at the joint position shown in next step becomes the same as atmospheric pressure.
  11. When fixing boot (1) to joint housing (2) with differential side boot big band (3), adjust so that measurements become as indicated. See Fig 7 .
Fig 1: Applying Grease To Joint
G00311467Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Filling Up Boot Side With Grease
G00311468Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Installing Dynamic Damper On LH Axle Shaft
G00311443Courtesy of SUZUKI OF AMERICA CORP.
Fig 4: Driving In Cage Using Pipe
G00311444Courtesy of SUZUKI OF AMERICA CORP.
Fig 5: Inserting Cage Into Joint Housing
G00311445Courtesy of SUZUKI OF AMERICA CORP.
Fig 6: Applying Grease Inside Of Joint Housing
G00311446Courtesy of SUZUKI OF AMERICA CORP.
Fig 7: Fixing Boot To Joint Housing
G00311469Courtesy of SUZUKI OF AMERICA CORP.
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