Front Axle Shaft: Reassembly

CAUTION:

To prevent any problem caused by washing solution, DO NOT wash boots. Degreasing boots with cloth is allowed.
Bend each boot band end against forward rotation.
DO NOT squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.

Fully apply joint grease to wheel side joint. See Fig 1 . Use joint grease in tube included in spare part.
On XL-7, use the following procedure:
- Install wheel side boot by fitting convex part (1) of boot onto concave part (2) of DOJ housing and shaft. See Fig 2 .
- Place new wheel side boot small band (1) onto boot putting band outer end (2) against forward rotation (3). See Fig 3 .
- Fasten boot small band by using the band compressor. See Fig 4 .
- Place new wheel side boot big band (1) onto boot putting band outer end (2) against forward rotation (2). See Fig 5 .
- Before fastening boot big band, insert screwdriver into boot on ball joint housing side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
- Fasten boot big band by using the band compressor. See Fig 4 .
Fig 1: Applying Joint Grease To Wheel Side Joint
Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Installing Wheel Side Boot
Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Identifying Installation Of Small Band
Courtesy of SUZUKI OF AMERICA CORP.

Fig 4: Fastening Boot Small Band
Courtesy of SUZUKI OF AMERICA CORP.

Fig 5: Placing New Wheel Side Boot Big Band
Courtesy of SUZUKI OF AMERICA CORP.
On Grand Vitara and Vitara, use the following procedure:
- Fit wheel side boot on shaft. Before fixing boot big and small bands, insert screwdriver into boot on ball joint housing side and allow air to enter boot so that air pressure in boot become the same as atmospheric pressure.
- Fix boot big and small bands. See Fig 6 .
Install differential side boot (1) onto axle shaft till its small diameter side fits to shaft groove and fix there with boot small band (2). See Fig 7 .
CAUTION: Install cage (1) directing smaller outside diameter side to shaft end.
Install cage (1) to shaft. See Fig 8 .
Install snap ring (1) by using snap ring pliers. See Figure .
Apply grease to entire surface of cage. See Fig 9 . Use joint grease in tube included in spare part.
Insert cage into DOJ housing and fit circlip (1) into groove of DOJ housing. See Fig 10 .
Apply grease in tube included in spare part to inside of DOJ housing, and fit differential side boot to DOJ housing. See Fig 11 . Fill up inside of differential side boot with grease.
CAUTION: Bend each boot band end against forward rotation (A). DO NOT squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
Fitting boot to DOJ housing, adjust measurement "b" and "c".
Before fixing boot big band, insert screwdriver into differential side boot on DOJ housing side and allow air to enter differential side boot so that air pressure in differential side boot becomes the same as atmospheric pressure.
Check differential side boot for distortion or dent. If any abnormality is found, fix it. If not, fasten boot big band.