Service Manual Update: Drive Center Shaft Disassembly And Reassembly Procedures (TS 03 03133)

Publication date: 2013-06-14
Reference number: TS 03 03133

SERVICE MANUAL UPDATE: DRIVE CENTER SHAFT DISASSEMBLY AND REASSEMBLY PROCEDURES

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 03 03133, Date of Issue: June 14, 2013

SUZUKI:	2010~2013 SX4 (RW420)
SECTION:	Driveline-Axle-Differential

CONDITION

This bulletin is being provided to inform you of service manual additions for Drive Center Shaft Disassembly and Reassembly Procedures for drive center shafts equipped with deflector. Additions apply to 2010~2013 SX4 (RW420) Service Manuals, Section 3A for 'Front Drive Shaft Components' and 'Center Shaft Assembly Disassembly and reassembly.

CORRECTION

Please refer to changes illustrated in the attached pages of this bulletin. The following table describes the corresponding section(s) that have been added/amended. The Online Service Manual has been revised prior to the release of this bulletin.

AFFECTED SERVICE MANUAL(S)

AFFECTED SERVICE MANUALS

Manual Name		Part Number	Corresponding Item
SX4 (RW420) Service Manual	2010 MY	99500-80J30-33E	Section 3A: Front Drive Shaft Components Section 3A: Center Shaft Assembly Disassembly and Reassembly
	2011 MY	99500-80J40-33E
	2012 MY	99500-80J50-33E
	2013 MY	99500-80J60-33E

Please refer to changes illustrated in the following pages.

3A-2 Drive Shaft/Axle: Front

Front Drive Shaft Symptom Diagnosis

Abnormal noise

Worn or breakage of the drive shaft joint Replace.
Worn or breakage of the center bearing Replace.

REPAIR INSTRUCTIONS

Front Drive Shaft Components

Front Drive Shaft Assembly On-Vehicle Inspection

Check boots for breakage or deterioration.
Check wheel side joint for rattle or smooth rotation.
Check differential side, center shaft side or transfer side joint for smooth rotation.
If any abnormality is found, replace.

Front Drive Shaft Assembly Removal and Installation

Reference: "Front Drive Shaft Assembly Component Location": Front

Reference: "Front Drive Shaft Assembly On-Vehicle Inspection": Front

Removal

Disconnect wheel speed sensor from steering knuckle.
- ABS model:
- ESP® model:
Remove drive shaft nut.
Drain transaxle oil.
- M/T model:
- CVT model:
For 4WD model, drain transfer oil.
Remove brake hose mounting bolt (1) and brake hose (2) from bracket and then detach wheel speed sensor harness (3) from strut bracket.
Disconnect stabilizer joint from front strut.
Disconnect tie-rod end from steering knuckle.
- Hydraulic P/S model:
- EPS model:
Disconnect front suspension arm ball joint stud from steering knuckle.
Using tire lever (1) or plastic hammer (3), pull out drive shaft joint (2) so as to release snap ring fitting of joint spline at differential side, at center shaft or at transfer.
Remove drive shaft assembly.
For 2WD model, remove center bearing support bolts (1) and center shaft assembly (2), if equipped.

13. Apply grease (including in spare parts) to inside of tripod joint housing (1), joint it with tripod joint.
Grease color

"A": Tan

Amount

"A": 85 - 105 g (3.2 - 3.8 oz)
14. Fit boot (1) to grooves of shaft and housing (2) adjust length to specification below.
Drive shaft boot fixing position (distance between housing end and small boot band)

Left side drive shaft "a": 184.0 - 194.0 mm (7.245 - 7.637 in,)

Right side drive shaft "b": 227.6 - 237.6 mm (8.961 - 9.354 in,) (M/T model)

Right side drive shaft "b": 226.1 - 236.1 mm (8.902 - 9.295 in,) (CVT model)
15. Insert screwdriver into boot and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure.
16. Fasten boot bands (1) as shown in figure.
CAUTION: Do not squeeze or distort boot when fastening it with bands. Distorted boot caused by squeezing air may reduce its durability.

Center Shaft Assembly Disassembly and Reassembly (2WD Model)

Reference: "Front Drive Shaft Assembly Removal and Installation": Front

Disassembly

Remove circlip (1) from center shaft (2).
Using hydraulic press (1), remove center shaft (2) with dust shield (3) from center bearing (4).
CAUTION: If shaft is pushed with base (5) put just under dust shield, dust shield will interfere with base and dust shield can damage.
Do not put base of hydraulic press just under dust shield.
Remove dust seal (1) from center bearing support using special tool.
Special tool

(A): 09913-50121
Remove snap ring (1) using snap ring pliers (2).
Using hydraulic press (2) and special tool, remove center bearing from center bearing support (1) by pushing the bearing from transaxle side.
Special tool

(A): 09913-75810
Remove deflector (1) and/or dust shield from center shaft using flat-bladed screwdriver or the like, if necessary.

Reassembly

Install new deflector (1) onto center shaft, if removed, by tapping flat-surface of deflector indicated by arrow in figure, along the circle little by little using flat-end rod covered with cloth (2) so as not to warp it.
CAUTION:
- Denting or scratching the oil seal contact surface of center shaft will oil leakage. Do not damage the contact surface when installing the deflector.
- Incomplete installation of the deflector will damage the oil seal and result in oil leakage.
  Confirm the deflector end (3) contacts with the shoulder (4) of the shaft evenly.
Install new dust shield (1) to center shaft using special tool, if removed.
Special tool

(A): 09927-66010
Using hydraulic press (2) and special tool, install new center bearing to center bearing support (1) by pushing the bearing from drive shaft side.
Special tool

(A): 09913-75520
Install new snap ring (1) in groove (2) of center bearing support.
Apply grease (2 - 3 g) to space on bearing as shown in figure.
"A": Grease 99000-25011 (SUZUKI Super Grease A)
Install new dust seal (1) to specified position on drive shaft side of center bearing support (2) in specified direction shown in figure using special tools.
Special tool

(A): 09926-27610

(B): 09924-74510

Distance

6MT model:

"a": 0.5 - 1.5 mm (0.02 - 0.05 in.)

CVT model:

"a": 0.0 -1.0 mm (0.00 - 0.04 in.)
Press-fit center shaft (2) into inner race (1) of center bearing from transaxle side using hydraulic press (3) and special tool.
Special tool

(A): 09913-84510
Install new circlip (1) to center shaft (2).

SPECIFICATIONS

Tightening Torque Specifications

NOTE: For fastener(s) with * (asterisk) below, refer to the specified procedure in "Repair Instructions ".

TIGHTENING TORQUE SPECIFICATION

Fastening part	Tightening torque			Note
Fastening part	N.m	kgf-m	lbf-ft	Note
Center bearing support bolt*	55	5.6	40.5	(T3A101)

Reference:

For the tightening torques of fasteners not specified in this page, refer to:

"Front Drive Shaft Assembly Component Location ": Front

SPECIAL TOOLS AND EQUIPMENT

Recommended Service Material

SPECIAL TOOLS AND EQUIPMENT DESCRIPTION

Material	SUZUKI recommended product or Specification		Note
Grease	SUZUKI Super Grease A	P/No.: 99000-25011	(M3A101)

NOTE: Required service materials are also described in:
"Front Drive Shaft Components": Front

Special Tool

SPECIAL TOOL

09913-50121 Oil seal remover (L3A104)	09913-75520 Bearing installer (L3A107)
09913-75810 Bearing installer (L3A105)	09913-84510 Bearing installer (L3A110)
09924-74510 Bearing and oil seal handle (L3A109)	09925-98220 Bearing installer (L3A103)
09926-27610 Oil seal installer (L3A108)	09927-66010 Oil pump aligner (L3A106)
09943-57011 Band compressor (L3A101)	09943-57021 Low-profile clamp pliers (L3A102)