Drive Intermediate Shaft Disassembly and Reassembly (2WD Model)
Drive Intermediate Shaft Disassembly and Reassembly (2WD Model)
Drive Intermediate Shaft Assembly Removal and Installation (2WD Model):Front
Disassembly
1) Remove circlip (1) from drive intermediate shaft (2).
2) Using hydraulic press (1), remove drive intermediate shaft (2) from intermediate shaft bearing.
NOTE:
In case of drive intermediate shaft equipped with dust shield, dust shield (3) is pushed together with drive intermediate shaft out of support (4) by press. If shaft is pushed with base put just under dust shield, dust shield will interfere with base and dust shield can damage.
Do not put bases of hydraulic unit just under dust shield.
3) Remove dust seal (1) from intermediate shaft bearing support using special tool.
Special Tool
(A): 09913-50121
4) Remove bearing support circlip (1) using snap ring pliers (2).
5) Using hydraulic press and special tool, remove intermediate shaft bearing from intermediate shaft bearing support (1) by pushing the bearing from transaxle side.
Special Tool
(A): 09913-75810
6) Remove dust cover (1) and/or dust shield from drive intermediate shaft using flat-bladed screwdriver or the like, if necessary.
Reassembly
1) Install new dust cover (1) onto drive intermediate shaft, if removed, by tapping flat-surface of dust cover 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.
NOTE: - Denting or scratching the oil seal contact surface of drive intermediate shaft will oil leakage.
Do not damage the contact surface when installing the dust cover.
- Incomplete installation of the dust cover will damage the oil seal and result in oil leakage.
Confirm the dust cover end (3) contacts with the shoulder (4) of the shaft evenly.
2) Install new dust shield (1) to drive intermediate shaft using special tool, if removed.
Special Tool
(A): 09945-55410
3) Using hydraulic press and special tool, install new intermediate shaft bearing to intermediate shaft bearing support (1) by pushing the bearing from drive shaft side.
Special Tool
(A): 09913-75520
4) Install new circlip (1) in groove (2) of intermediate shaft bearing support.
5) Apply grease to space on bearing as shown in figure.
"A" Grease: 99000-25011 (SUZUKI Super Grease A)
6) Install new dust seal (1) to specified position on drive shaft side of intermediate shaft 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.)
7) Press-fit drive intermediate shaft (2) into inner race (1) of intermediate shaft bearing from transaxle side using hydraulic press and special tool.
Special Tool
(A): 09913-84510
8) Install new circlip (1) to drive intermediate shaft (2).