Intermediate Shaft, Joint and Dash Seal Installation

1. Install the intermediate shaft into the vehicle.
Fig 1: Installing Intermediate Shaft Into Vehicle
Courtesy of SUZUKI OF AMERICA CORP.
2. Install the dash seal retaining ring with the nuts.
   1. Tighten the dash seal retaining ring nuts to 7 N.m (62 lb-in).
Fig 2: Installing Dash Seal Retaining Ring With Nuts
Courtesy of SUZUKI OF AMERICA CORP.
3. Attach the upper universal joint of the intermediate shaft onto the steering column.
   CAUTION: When attaching the upper universal joint, the steering wheel must be placed in the straight-ahead position with the spokes pointing down.
4. Install the pinch bolts into the upper universal joint on the intermediate shaft and tighten the bolts.
   1. Tighten the intermediate shaft pinch bolts to 25 N.m (18 lb-ft).
Fig 3: Installing Pinch Bolts Into Upper Universal Joint
Courtesy of SUZUKI OF AMERICA CORP.
5. Attach the lower universal joint of the intermediate shaft onto the steering gear stub shaft.
   CAUTION: When attaching the lower universal joint, the marks on the intermediate shaft and on the stub shaft should line up.
Fig 4: Attaching Lower Universal Joint Of Intermediate Shaft
Courtesy of SUZUKI OF AMERICA CORP.
6. Install the bolt into the lower universal joint on the intermediate shaft and tighten the bolt.
   CAUTION: When installing the lower intermediate shaft pinch bolt, make sure the bolt goes through the universal joint on the side of the stub shaft with the notch. If you have trouble seating the universal joint completely down onto the stub shaft, rotate the steering wheel slightly while pushing down on the universal joint.
   1. Tighten the intermediate shaft pinch bolt to 25 N.m (18 lb-ft).

Fig 5: Installing Bolt Into Lower Universal Joint On Intermediate Shaft

Courtesy of SUZUKI OF AMERICA CORP.