Front Drive Shaft Disassembly and Assembly: Assembly

Judging from abnormality noted before disassembly and what is found through visual check of component parts after disassembly, prepare replacing parts and proceed to reassembly.

Make sure that tripod joint housing is washed thoroughly and air dried.

Replace boot with new one.

1. Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2. Clean boots with cloth.
3. Set new differential side small band and new differential side boot (1) on shaft temporarily, and then apply grease to tripod joint (2). Use specified grease in tube included in spare parts.
4. Install tripod joint spider (3) on shaft using special tool with hammer, directing its chamfered spline toward wheel side, and then fasten it with new snap ring (4) using snap ring plier (5).

   Special Tool 

   1. 09913-80113 
      Fig 1: Identifying Snap Ring

      Courtesy of SUZUKI OF AMERICA CORP.
5. Apply grease (including in spare parts) to inside of tripod joint housing (1), joint it with tripod joint.

   Grease color 

   "A": Yellow 

   Amount 

   "A": 127 - 137 g (4.5 - 4.8 oz) (right side) 

   "A": 170 - 180 g (6.0 - 6.3 oz) (left side) 

   Fig 2: Applying Grease To Joint Housing

   Courtesy of SUZUKI OF AMERICA CORP.
6. Fit boot to grooves of shaft and housing.
7. Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
   CAUTION:

   • Bend each boot band against forward rotation.
   • Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.
8. Place differential side boot new big band (3) and new small band (4) onto boot putting band outer end (1) against forward rotation (2) as shown in figure.
   Fig 3: Placing Differential Side Boot Big Band

   Courtesy of SUZUKI OF AMERICA CORP.
9. Fasten differential side boot big band.
   • For differential side boot big band

     Fasten band (1) by drawing hooks (2) with special tool and engage hooks (3) in slot and window (4).

     Special Tool 

     1. 09943-57010 
   • For differential side boot small band

     Fasten band (5) securely using special tool.

     NOTE: Fasten boot small band securely until complete contact "a" is obtained.

     Special Tool 

     1. 09943-57010 
     Fig 4: Identifying Special Tool On Boot Band

     Courtesy of SUZUKI OF AMERICA CORP.