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Home >> Suzuki Truck >> 2012 >> Equator 4WD V6-4.0L >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Service and Repair >> Overhaul

Overhaul




Drive Shaft: Disassembly and Assembly










Disassembly

Final Drive Side

1) Mount the drive shaft in a vise.

CAUTION:
When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the drive shaft.

2) Remove boot bands and slide the boot back.
3) Put matching marks on housing and shaft before separating joint assembly.

CAUTION:
Use paint or similar substance for matching marks. Do not scratch the surfaces.

4) Remove the stopper ring using a suitable tool as shown, and pull the housing off.





5) Remove the snap ring using a suitable tool, then remove the ball cage, steel ball, and inner race assembly from the shaft.





6) Remove the boot from the shaft.
7) Remove circlip and dust cover from the housing.
8) Clean the old grease off of the housing using paper towels.

Wheel Side

9) Mount the drive shaft in a vise.

CAUTION:
When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the drive shaft.

10) Remove the boot bands and slide the boot back.
11) Screw a sliding hammer or suitable tool 30 mm (1.18 in) or more into threaded part of joint sub-assembly. Pull joint sub-assembly off of shaft as shown.






NOTE:
Align the sliding hammer and shaft and remove the joint sub-assembly by pulling directly.

CAUTION:
- If the joint sub-assembly cannot be removed after five or more unsuccessful attempts, replace the entire drive shaft assembly.

12) Remove boot from the shaft.
13) Remove circlip from the shaft.
14) While rotating the ball cage, clean the old grease off of the joint sub-assembly using paper towels.

Inspection after Disassembly

Shaft

- Replace the shaft if there is any bending, cracking, or other damage.

Joint Sub-assembly

- Check for any rough rotation or unusual axial looseness.
- Clean any foreign material from inside the joint sub-assembly.
- Check for any compression scars, cracks, or fractures.

CAUTION:
If any irregular conditions are found in the joint sub-assembly components, replace the entire joint sub-assembly.

Housing

NOTE:

Housing, ball cage, steel ball, and inner race are in a set.

- Check for any compression scars, cracks, fractures, or unusual wear on the ball rolling surface.
- Check for any deformation of the boot installation components.

Ball Cage

- Check the sliding surface for any compression scars, cracks, or fractures of sliding surface.

Steel Ball

- Check for any compression scars, cracks, fractures, or unusual wear.

Inner Race

- Check the ball sliding surface for any compression scars, cracks, or fractures.

- Check for any damage to the serrated part.

Assembly

Final Drive Side

1) Wrap the serrated part of the shaft with tape. Install the boot band and boot to shaft.






NOTE:
Discard the old boot band and boot and use a new one for assembly.

2) Remove the tape wound around the serrated part of the shaft.
3) Install the ball cage, steel ball, and inner race assembly on the shaft, and secure them using the snap ring.






NOTE:
Discard the old snap ring and use a new one for assembly.

4) Insert the specified quantity of genuine grease or equivalent, into the housing. Refer to [Recommended Fluids and Lubricants [for USA and Canada] [1][2]Maintenance ] (United States and Canada), [Recommended Fluids and Lubricants [for Mexico] ] (Mexico).





[Recommended Fluids and Lubricants [for USA and Canada] Front Axle





CAUTION:
If grease adheres to the boot mounting surface (indicated by * marks) on shaft and housing, boot may come off. Remove all grease from surfaces.

5) Install the stopper ring onto the housing.

CAUTION:
- Do not reuse stopper rings.
- Make sure that housing and stopper ring are fully engaged.

6) Install the boot securely into the grooves (indicated by * marks) as shown.






CAUTION:
If there is grease on boot mounting surfaces (indicated by * marks) of shaft and housing, boot may come off. Remove all grease from surfaces.

7) Check that the boot installation length (L) is the length indicated below. Insert a suitable tool into the large end of the boot. Bleed air from boot to prevent boot deformation.
Front Axle





CAUTION:
- The boot may break if the boot installation length is less than the specified value.
- Do not to touch the tip of the suitable tool to the inside of the boot.

8) Secure the big and small ends of the boot with the new boot bands as shown.






NOTE:
Discard not reuse boot bands.

9) Secure housing and shaft and then make sure that they are in the correct position when rotating boot. Use a new boot band if the boot band needs to be loosened to reposition the boot.
10) Install circlip and dust cover to housing.

NOTE:
Do not reuse circlip and dust cover.

Wheel Side

11) Insert the genuine grease or equivalent, into the joint sub-assembly serration hole until the grease begins to ooze from the ball groove and serration hole. Refer to [1][2]Maintenance ] (United States and Canada), [Recommended Fluids and Lubricants [for Mexico] ] (Mexico). After inserting the grease, use a shop cloth to wipe off the grease that has oozed out.





12) Wrap the serrated part of the shaft with tape. Install the boot band and boot onto the shaft. Do not damage the boot.






NOTE:
Discard the old boot band and boot and use a new one for assembly.

13) Remove the protective tape wound around the serrated part of the shaft.
14) Attach the circlip to the shaft. The circlip must fit securely into the shaft groove. Attach the nut to the joint sub-assembly.





Use a soft hammer to press-fit the circlip.

NOTE:
Discard the old circlip and use a new one for assembly.

15) Insert the specified quantity of genuine grease or equivalent, into the joint sub-assembly and the large end of the boot. Refer to [Recommended Fluids and Lubricants [for USA and Canada] [1][2]Maintenance ] (United States and Canada), [Recommended Fluids and Lubricants [for Mexico] ] (Mexico).





Front Axle





CAUTION:
If grease adheres to the boot mounting surface (indicated by * marks) on shaft and housing, boot may come off. Remove all grease from surfaces.

16) Install the boot securely into the grooves (indicated by the * marks) as shown.

CAUTION:
If there is grease on the boot mounting surfaces (indicated by the * marks) of the shaft and joint sub-assembly, the boot may come off. Remove all grease from the drive shaft surfaces.





17) Check that the boot installation length (L) is the specified length. Insert a suitable tool into the big side of the boot. Bleed the air from the boot to prevent boot deformation.
Front Axle





CAUTION:
- The boot may break if the boot installation length is less than the specified length.
- Do not contact inside surface of boot with the tip of the suitable tool.

18) Secure large and small ends of the boot using new boot bands using tool as shown.











NOTE:
Do not reuse boot bands.

- Secure boot band so that dimension (M) meets specification as shown.





Front Axle





19) After installing the housing to the shaft, rotate the boot to check that it is positioned correctly. If the boot is not positioned correctly, remove the old boot bands then reposition the boot and secure the boot with new boot bands.

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