Suzuki Grand Vitara JB416 / JB420. Manual - part 160

3A-2 Drive Shaft / Axle: Front

Repair Instructions

Front Drive Shaft Boot and Joint Check

S5JB0A3116001

• Check boot for tear. If even a small tear is found, replace with new one.

• Check drive shaft joint for wear, breakage, and any other damage. Replace if any abnormality is found.

Front Drive Shaft Components

S5JB0A3116002

I5JB0A311001-01

I5JB0A311002-03

[A]: Right side drive shaft assembly

4. Boot band (Large)

9. Drive shaft nut

: After tightening nut, caulk nut 
securely.

[B]: Left side drive shaft assembly

5. Boot (Differential side)

10. Front drive shaft flange nut

1. Circlip

6. Boot band (Small) 

: 220 N

⋅m (22.0 kgf-m, 159.5 lb-ft)

2. Differential side joint (Constant velocity tripod joint)

: Apply yellow grease included in spare part to joint.

7. Wheel side joint assembly (Constant velocity 

ball joint)
: Never disassemble.

: 80  N

⋅m (8.0 kgf-m, 58.0 lb-ft)

3. Snap ring

8. Tripod joint spider

: Do not reuse.

Drive Shaft / Axle: Front 3A-3

Front Drive Shaft Assembly Removal and 
Installation

S5JB0A3116003

Removal

1) Undo caulking (1) and remove drive shaft nut (2).

2) Hoist vehicle and remove wheel.
3) Drain front differential oil.
4) Disconnect tie-rod end from steering knuckle 

referring to “Steering Knuckle Removal and 
Installation in Section 2B”.

5) Remove stabilizer joint from stabilizer bar.
6) Remove brake hose mounting bolt.
7) Remove suspension control arm referring to 

“Suspension Control Arm Removal and Installation 
in Section 2B”.

8) Remove front drive shaft flange nuts (1).

9) Remove drive shaft assembly from front differential.

CAUTION

!

 

To prevent breakage of boots (wheel side and 
differential side), do not contact them with 
other parts when removing drive shaft 
assembly.

 

Installation

CAUTION

!

 

• Be careful not to damage oil seals and 

boots when installing drive shaft.

• Do not hit joint boot with hammer.

Inserting joint only by hands is allowed.

• Make sure that differential side joint is 

inserted fully and its snap ring is seated as 
it was.

 

Install drive shaft assembly by reversing removal 
procedure and noting the following points.
• Tighten each bolts and nuts to the specified torque 

referring to “Front Drive Shaft Components: Front” 
and “Front Suspension Construction in Section 2B”.

Front Drive Shaft Disassembly and Assembly

S5JB0A3116004

Disassembly

CAUTION

!

 

• Disassembly of wheel side joint assembly 

is not allowed. If any noise or damage 
exists in it, replace it as assembly.

• Do not disassemble tripod joint spider. If 

any malcondition is found in it, replace it 
as differential side joint assembly.

 

1) Draw hooks (2) of boot big band together and 

remove differential side boot big band (1).

I5JB0A311003-01

1

I5JB0A311004-01

I5JB0A311005-01

3A-4 Drive Shaft / Axle: Front

2) Wipe off grease from shaft and take off snap ring (1) 

using snap ring plier (2).

3) Remove tripod joint spider (1) using 3 arms puller 

(2).

CAUTION

!

 

To prevent any problem caused by washing 
solution, do not wash tripod joint except its 
housing. Degreasing of tripod joint with cloth 
is allowed.

 

4) Remove differential side boot small band, and then 

pull out differential side boot from shaft.

Assembly
Judging from abnormality noted before disassembly and 
what is found through visual check of component parts 
after disassembly, prepare replacing parts and proceed 
to reassembly.
Make sure that tripod joint housing is washed thoroughly 
and air dried.
Replace boot with new one.

CAUTION

!

 

• Do not wash boots in degreaser such as 

gasoline or kerosene. etc. Washing in 
degreaser causes deterioration of boot.

• To ensure full performance of joint as 

designed, apply grease of specified 
volume and color to joint.

 

1) Wash disassembled parts (except boots). After 

washing, dry parts completely by blowing air.

2) Clean boots with cloth.
3) Set new differential side small band and new 

differential side boot (1) on shaft temporarily, and 
then apply grease to tripod joint (2). Use specified 
grease in tube included in spare parts.

4) Install tripod joint spider (3) on shaft using special 

tool with hammer, directing its chamfered spline 
toward wheel side, and then fasten it with new snap 
ring (4) using snap ring plier (5).

Special tool
(A):  09913–80113

I5JB0A311008-01

I3RH0A311004-01

I5JB0A311009-01

Drive Shaft / Axle: Front 3A-5

5) Apply grease (including in spare parts) to inside of 

tripod joint housing (1), joint it with tripod joint.

Grease color
“A”: Yellow

Amount
“A”: 127 – 137 g (4.5 – 4.8 oz) (right side)
“A”: 170 – 180 g (6.0 – 6.3 oz) (left side)

6) Fit boot to grooves of shaft and housing.
7) Insert screw driver into boot and allow air to enter 

boot so that air pressure in boot becomes the same 
as atmospheric pressure.

CAUTION

!

 

• Bend each boot band against forward 

rotation.

• Do not squeeze or distort boot when 

fastening it with bands. Distorted boot 
caused by squeezing air may reduce its 
durability.

 

8) Place differential side boot new big band (3) and new 

small band (4) onto boot putting band outer end (1) 
against forward rotation (2) as shown in figure.

9) Fasten differential side boot big band.

• For differential side boot big band

Fasten band (1) by drawing hooks (2) with special 
tool and engage hooks (3) in slot and window (4).

Special tool
(A):  09943–57010

• For differential side boot small band

Fasten band (5) securely using special tool.

NOTE
Fasten boot small band securely until 
complete contact “a” is obtained.

 

Special tool
(A):  09943–57010

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I5JB0A311006-01

(A)

1

4

2

3

(B)

5

“a”

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