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Home >> Suzuki >> 2008 >> XL7 Base, AWD >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts >> Drive Shaft/Axle >> Repair Instructions >> Front Wheel Drive Shaft Replacement >> Installation Procedure
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Installation Procedure

Fig 1: Identifying Wheel Drive Shaft Retaining Ring To Output Shaft
G05469349Courtesy of SUZUKI OF AMERICA CORP.
  1. Install a new wheel drive shaft retaining ring to the output shaft.
    Fig 2: Identifying Wheel Drive Shaft Oil Seal
    G05469350Courtesy of SUZUKI OF AMERICA CORP.
  2. Install the J 44394 to the wheel drive shaft oil seal.
    Fig 3: Identifying Wheel Drive Shaft To Output Shaft
    G05469351Courtesy of SUZUKI OF AMERICA CORP.
  3. Install the wheel drive shaft to the output shaft:
    • Guide the wheel drive shaft tripot joint squarely onto the output shaft.
    • After the splined end of the wheel drive shaft passes the oil seal, remove the J 44394 from the oil seal.
    • Firmly engage the wheel drive shaft to the output shaft.
    • Ensure that the tripot joint is fully seated on the output shaft by grasping the tripot joint and attempting to pull free of the output shaft.
      Fig 4: Identifying Wheel Drive Shaft Spindle Nut
      G05469352Courtesy of SUZUKI OF AMERICA CORP.
  4. Insert the constant velocity (CV) joint spindle to the wheel hub/bearing assembly of the steering knuckle.
  5. Hand install a new wheel drive shaft spindle nut.
    Fig 5: Identifying Lower Ball Joint Stud To Steering Knuckle
    G05469353Courtesy of SUZUKI OF AMERICA CORP.
  6. Install the lower ball joint stud to the steering knuckle.
    CAUTION: Refer to FASTENER NOTICE .
  7. Install the lower ball joint nut to the stud.

    Tightening torque 

    Tighten the nut to 40 N.m (30 lb ft)  .

  8. Install the cotter pin to the ball joint stud.
  9. If necessary, tighten the nut one additional flat at a time until the castle nut aligns with the hole in the ball joint stud.
  10. Secure the cotter pin to the ball joint stud by folding one tine over the end of the ball joint stud.
  11. Cut off any excess length of the cotter pin tines.
    Fig 6: Identifying Lower Link To Stabilizer Bar
    G05469354Courtesy of SUZUKI OF AMERICA CORP.
  12. Install the lower link to the stabilizer bar.
  13. Install a new nut to the stabilizer bar link stud.
    NOTE: In order to prevent damaging the stabilizer bar link stud seal, do not allow the stud to rotate while tightening the nut.
  14. Use a back up wrench on the stud and tighten the nut.

    Tightening torque 

    Tighten the nut to 65 N.m (48 lb ft)  .

    Fig 7: Identifying Tie Rod End To Steering Knuckle
    G05469355Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the tie rod end to the steering knuckle.
  16. Using the J 44015, pull the stud into steering knuckle.

    Tightening torque 

    Tighten the J 44015 to 40 N.m (30 lb ft)  .

  17. Remove the J 44015 from the tie rod end stud.
    Fig 8: Identifying Tie Rod End Stud
    G05469356Courtesy of SUZUKI OF AMERICA CORP.
  18. Install a new nut to the tie rod end stud.

    Tightening torque 

    Tighten the nut to 25 N.m (18 lb ft) plus 90 degrees  .

  19. Tighten the wheel drive shaft spindle nut.

    Tightening torque 

    Tighten the nut to 205 N.m (151 lb ft)  .

    Fig 9: Identifying Tire And Wheel Assembly
    G05469357Courtesy of SUZUKI OF AMERICA CORP.
  20. Install the tire and wheel assembly. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
  21. Lower the vehicle.
  22. Inspect the transmission fluid level. Refer to TRANSMISSION FLUID CHECK .
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