Drive Axle Assembly Installation

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.

Clean the hub seal and the transaxle seal.
NOTE: Do not damage the seals.
Install the intermediate axle shaft into the transaxle.
Tighten:

Tighten the intermediate axle shaft mounting bolts to 52 N.m (38 lb-ft).
Install the drive axle into the intermediate axle shaft.
Install the wheel hub onto the axle shaft.

Fig 1: Identifying Intermediate Axle Shaft Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Mount the steering knuckle onto the lower ball joint.

Fig 2: Mounting Steering Knuckle Onto Lower Ball Joint
Courtesy of SUZUKI OF AMERICA CORP.
Install the tie rod into the knuckle / strut and install the tie rod nut.
Tighten:

Tighten the tie rod nut to 50 N.m (37 lb-ft).

Fig 3: Identifying Tie Rod
Courtesy of SUZUKI OF AMERICA CORP.
Install the lower ball joint bolt and nut.
Tighten:

Tighten the lower ball joint bolt and nut to 105 N.m (77 lb-ft).

Fig 4: Identifying Lower Ball Joint Bolt And Nut
Courtesy of SUZUKI OF AMERICA CORP.
Loosely install the washer and a new axle shaft caulking nut. Always use a new nut.
Tighten the axle shaft caulking nut to 320 N.m (236 lb-ft).
Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
Install the wheels. Loosely install the nuts. Refer to WHEEL AND TIRES -- VERONA .
Lower the vehicle to the floor.
Tighten:

Tighten the wheel nuts to 100 N.m (74 lb-ft).
Refill the transaxle fluid to the proper level. Refer to TRANSAXLE FLUID LEVEL CHECK .

Fig 5: Identifying Axle Shaft Caulking Nut
Courtesy of SUZUKI OF AMERICA CORP.