Suzuki Aerio, Verona 2002-06

Lower Ball Joints

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Removal & Installation



  1. Remove the front wheels.
  2.  
  3. Remove the bolt for the drive shaft. Use a prybar in the brake disc as counterhold.
  4.  
  5. Remove the drive shaft from the hub by tapping out the drive shaft with a brass drift.
  6.  
  7. Fold aside the spring strut.
  8.  
  9. Loosen the ball joint pin from the link arm. Use tool 999 7062.

    Click image to see an enlarged view

    Fig. Loosen the ball joint pin from the link arm-2005-06

  10.  
  11. Install the cap nut for the ball joint pinion. For earlier versions (deep thread pitch) use 999 7062 and for later versions (closer thread pitch) use 999 7231.
  12.  
  13. Tighten the nut against the link arm.
  14.  
  15. Then turn back one turn so that clearance is created between the cap nut and link arm.
  16.  
  17. Place the puller on the link arm and loosen the ball joint from the link arm.
    NOTE
    If the catch is placed by (2), the rubber gaiter on the ball joint may be damaged.

  18.  
  19. Press the control arm down using lever 999 7076. Position the hook at (1).

    Click image to see an enlarged view

    Fig. Press the control arm down using lever 999 7076-2005-06

  20.  
  21. Disconnect the spring strut from the link arm.
  22.  
  23. Remove the ball join bolts.

    Click image to see an enlarged view

    Fig. Ball joint bolts-2005-06



    Click image to see an enlarged view

    Fig. Ball joint removal-2005-06

  24.  
  25. Install the nut on the ball joint. Use 999 7149 for earlier versions (deep thread pitch) and for later versions (closer thread pitch) use 999 7230.
  26.  
  27. Tap loose the ball joint.
    CAUTION
    Always use safety glasses. Clean both in the seat for the ball joint and the contact surfaces with a rotating steel brush. Grease the seat with wheel bearing grease.

  28.  

To install:


NOTE
The guide bolts 999 5781 have a wrench grip (see arrow) which is asymmetrically positioned.



Click image to see an enlarged view

Fig. The guide bolts 999 5781 have a wrench grip (see arrow) which is asymmetrically positioned-2005-06


NOTE
Use the bolt (2) with the shortest distance from the wrench grip.


NOTE
Leave the ball joint's protective cup on to avoid damaging the rubber gaiter.

  1. Install the new ball joint loosely using the guide bolts.

    Click image to see an enlarged view

    Fig. Install the new ball joint loosely using the guide bolts-2005-06

  2.  
  3. Press up the ball joint against the seat with press tool 999 5796.
  4.  
  5. Check that the ball joint is centered in the seat.

    Click image to see an enlarged view

    Fig. Drive in the ball joint with a copper hammer-2005-06

  6.  
  7. Drive in the ball joint with a copper hammer.
  8.  
  9. Remove the guide bolts.
  10.  
  11. Tighten down the ball joint with the new bolts. Tighten to 74 ft. lbs. (100 Nm).

    Click image to see an enlarged view

    Fig. Tighten down the ball joint with the new bolts-2005-06

  12.  
  13. Remove the protective cup.
  14.  
  15. Install the halfshaft.
    WARNING
    If the catch is placed by (2), the rubber gaiter on the ball joint may be damaged.

  16.  
  17. Press down the link with lever 999 7076.
  18.  
  19. Place the catch by (1).
  20.  
  21. Install the spring strut in the link arm.
    NOTE
    The ball joint pin may not rotate. Use a bit Torx as counterhold in order to prevent damaging the rubber gaiter.

  22.  
  23. Use 999 5500 as adapter for the torque wrench.

    Click image to see an enlarged view

    Fig. Tightening the stud nut-2005-06

  24.  
  25. Install the nut. Tighten according to 37 ft. lbs. (50 Nm) plus 35°.
  26.  
  27. Install the wheels.
  28.  

The lower ball joint is an integral part of the lower control arm assembly. If the ball joint is found to be defective the whole lower control arm assembly must be replaced.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the control arm.
  4.  
  5. Drill off the heads of the three rivets with a 0.47 inch (12mm) drill bit.
  6.  
  7. Punch out the rivets with a drift.

    Click image to see an enlarged view

    Fig. Drilling off the ball joint rivets

  8.  

To install:

  1. Connect the ball joint to the control arm by inserting 3 ball joint bolts from below the control arm.
  2.  
  3. Tighten the ball joint-to-control arm nuts to 81 ft. lbs. (110 Nm).
  4.  
  5. Install the control arm.
  6.  

 
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