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    Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

    Knuckle and Spindle

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    REMOVAL & INSTALLATION



    Samurai Models

    See Figure 1

    1. Remove the front wheel hub, as described later in this section.
    2.  
    3. Loosen the king pin upper and lower retaining bolts, but do NOT remove the king pins at this time.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 1: Cross-sectional view of the Samurai steering knuckle and related components

    1. Remove the brake rotor dust cover, brake caliper holder and the wheel spindle from the knuckle.
    2.  
    3. Loosen the tie rod end castle nut, then disengage the tie rod end from the knuckle arm with a tie rod end separator tool.
    4.  
    5. Remove all of the joint seal bolts, then pull the oil seal cover, pad, oil seal and retainer from the knuckle.
    6.  
    7. Identify the upper and lower king pins with white paint or correction fluid, then remove both king pins from the knuckle. When removing the king pins, count the number of shims under each king pin; the same amount of shims must be installed as were removed.
    8.  
    9. Carefully pull the steering knuckle off of the front drive axle. When pulling the knuckle off of the axle, catch the lower king pin bearing when it falls off.. Be sure to identify the upper and lower king pins during disassembly so that they can be reinstalled in their original positions.
    10.  

    To install:
    1. Inspect the steering knuckle oil seal for wear or damage. If any defects are found, replace the seal with a new one. The oil seal used at the spherical sliding joint between the knuckle and the inner case accomplishes the additional purpose of keeping out road dust and as acting as a damper from the steering wheel. As this seal wears, its damping effect decreases, which causes the front wheels to develop a tendency to "shimmy."
    2.  
    3. Apply Suzuki Super Grease A (99000-1010) or equivalent, to the king pin bearing rollers.
    4.  
    5. Install the king pin bearings and slide the steering knuckle fully onto the front drive axle.
    6.  
    7. Install the proper amount of shims on each of the king pins, apply Suzuki Sealing Compound 366E (99000-7090) or its equivalent to the king pins as shown in the accompanying illustration. Install the king pins into the steering knuckle.
    8.  

    Before installing a new steering knuckle oil seal, ensure to apply Suzuki Super Grease A (99000-1010) or its equivalent to the oil seal lip.

    1. Install the oil seal retainer, oil seal, pad, and oil seal cover onto the steering knuckle. Start the oil seal cover bolts by hand, then tighten them to 71-106 inch lbs. (8-12 Nm).
    2.  
    3. Attach the tie rod end to the knuckle arm, then tighten the tie rod end castle nut to 22-39 ft. lbs. (6-55 Nm). Insert a new cotter pin through the castle nut and tie rod end stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the tie rod end stud hole, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
    4.  
    5. Apply Sealing Compound 366E (99000-7090) or equivalent to the mating surfaces of the brake caliper holder and the steering knuckle.
    6.  
    7. Install the wheel spindle, brake caliper holder, and the brake rotor dust cover onto the knuckle.
    8.  
    9. Apply thread locking compound (such as Suzuki Lock Cement 1102 - 99000-8050) to the king pin retaining bolt threads, then install the retaining bolts. Tighten the king pin upper and lower retaining bolts to .
    10.  
    11. Install the front wheel hub, as described later in this section.
    12.  

    OIL SEAL REPLACEMENT

    See Figures 2, 3 and 4

    This procedure is designed to allow you to replace your damaged or leaking steering knuckle oil seal without removing the knuckle from the vehicle.

    1. If additional undervehicle clearance is needed, apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 2: Remove the eight oil seal retaining ring attaching bolts and slide the ring, packing and seal back. Cut the old seal to remove it

    1. Remove the eight oil seal retaining bolts from the inboard side of the joint.
    2.  
    3. Slide the oil seal cover and felt packing inward on the drive axle housing.
    4.  
    5. Cut the old oil seal in half and remove it from the joint. Discard the old seal.
    6.  
    7. Using a pair of scissors, cut the new oil seal in one spot, as shown in the accompanying illustration.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 3: Cut one part of the new seal and fit it around the axle with the cut facing upwards

    1. Install the new seal in the retainer, ensuring that the cut portion of the seal is positioned upward and approximately 6 degrees from the matching face of the oil seal retainer.
    2.  
    3. Apply grease (such as Suzuki Super Grease H-99000-1120) to the inside of the oil seal, then apply sealing compound (such as Suzuki Sealing Compound "Cemedine" 366E-99000-7090) to the mating surface around the entire circumference of the oil seal; this will help prevent the entry of water into the joint.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 4: Apply sealer and grease to the seal and retaining plate as shown

    1. Install the felt packing and oil seal cover against the oil seal, then install the eight retaining bolts. Tighten the bolts in a crisscross pattern to 71-106 inch lbs. (8-12 Nm).
    2.  
    3. If necessary, lower the vehicle and remove the wheel blocks.
    4.  

    Sidekick, Tracker, Sidekick Sport and X-90 Models

    See Figures 5, 6, 7, 8, 9 and 10

    1. Loosen all of the front wheel lug nuts 1 / 2 turn.
    2.  
    3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
    4.  
    5. Remove the front wheel.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 5: To remove the steering knuckle, remove the two lower strut-to-knuckle bolts and the lower ball joint castellated nut

    1. Position a hydraulic floor jack beneath the lower control arm, then raise the floor jack until it supports the lower control arm.
    2.  
    3. Remove the wheel hub, as described later in this section.
    4.  
    5. Detach the tie rod end from the steering knuckle arm.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 6: Detach the lower ball joint stud from the steering knuckle by tapping the knuckle with a mallet, or use a ball joint separator tool

    1. Secure the bottom of the coil spring to the lower control arm with a chain. This will prevent the spring from accidentally dislodging form the control arm and possibly causing personal injury.
    2.  
    3. Withdraw the lower ball joint castle nut cotter pin, then remove the castle nut.
    4.  
    5. Remove the lower strut-to-steering knuckle bolts and nuts.
    6.  
    7. Detach the lower ball joint from the steering knuckle by tapping its end with a mallet, or by using a ball joint separator tool.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 7: Exploded view of the steering knuckle and related components

    1. While slowly lowering the floor jack, remove the spindle/knuckle assembly from the vehicle.
    2.  
    3. If necessary, remove the knuckle oil seal, dust cover and wheel spindle from the steering knuckle.
    4.  

    To install:
    1. Clean all spindle/knuckle components thoroughly.
    2.  
    3. Apply Suzuki Sealant 99000-7110 or its equivalent to the wheel spindle and steering knuckle mating surfaces.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 8: When installing the spindle to the knuckle, apply sealer to surface (A) and grease in recess (B). Make sure to use the proper types

    1. Fill the wheel spindle recess with approximately 0.35 oz. (10g) of lithium grease (such as Suzuki Grease 99000-1010).
    2.  
    3. Install the spindle onto the knuckle, then tighten the spindle-to-knuckle bolts to 36 ft. lbs. (50 Nm).
    4.  



    Click image to see an enlarged view

    Fig. Fig. 9: Use a seal driver tool (B and C) to install a new knuckle oil seal

    1. Using a seal driver tool (such as Suzuki Tools 09944-66010 and 09924-74510), install a new knuckle oil seal into the inboard side of the knuckle. Drive the new seal into the knuckle until its inner edge contacts the stepped surface of the knuckle.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 10: Apply lithium grease (B) to the oil seal lip and its cavity as shown

    1. Apply lithium grease to the oil seal lip and into the oil seal hollow until it is approximately 60% full.
    2.  
    3. While slowly raising the floor jack, position the spindle/knuckle assembly onto the lower ball joint stud and between the strut brackets.
    4.  
    5. Install the lower strut-to-steering knuckle bolts and nuts hand-tight.
    6.  
    7. Install and tighten the ball joint castle nut to 9-50 ft. lbs. (45-70 Nm). Insert a new cotter pin through the castle nut and ball joint stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the ball joint stud hole, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
    8.  
    9. Tighten the lower strut-to-steering knuckle mounting bolts and nuts to 58-75 ft. lbs. (80-100 Nm).
    10.  
    11. Remove the chain securing the coil spring to the lower control arm.
    12.  
    13. Attach the tie rod end to the steering knuckle arm, then tighten the tie rod end castle nut to 22-39 ft. lbs. (6-55 Nm). Insert a new cotter pin through the castle nut and tie rod end stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the tie rod end stud hole, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
    14.  
    15. Install the wheel hub, as described later in this section.
    16.  
    17. Lower the floor jack and remove it from beneath the lower control arm.
    18.  
    19. Install the front wheel.
    20.  
    21. Lower the vehicle and remove the rear wheel blocks.
    22.  
    23. Tighten all of the front wheel lug nuts.
    24.  

     
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