Suzuki Aerio, Verona 2002-06

Steering Knuckle

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove front wheel.
  6.  
  7. Remove or disconnect the following:

    The anti-roll bar link from the spring strut. Use a fixed wrench as a counterhold
     
    The ABS sensor. Hang up the sensor using a piece of wire
     
    The ABS sensor cable from the spring strut
     
    The brake caliper mounting bolts. Hang the caliper up using a piece of wire
     
    The halfshaft bolt. Use a screwdriver as a counterhold on the brake disc
     
    The locating pin holding the brake disc
     
    The brake disc. Detach the end of the halfshaft in the hub by knocking the drive shaft into the hub approximately 1 / 3 - 1 / 2 inch (10-15mm). Use a rubber or copper mallet
     
    The tie rod ends from the steering arm
     

  8.  
  9. Measure the position of the steering knuckle and spring strut for installation purposes.
  10.  
  11. Remove the bolts retaining the spring strut and the steering knuckle.

    Click image to see an enlarged view

    Fig. Location of bolt removal of steering knuckle

  12.  
  13. Press out the steering knuckle. At the same time pull the halfshaft from the transaxle.
  14.  
  15. Suspend the drive shaft from a hook 999 5045.
    NOTE
    Take care not to damage the halfshaft boot.



    Click image to see an enlarged view

    Fig. Suspending halfshaft from hook 999 5045

  16.  
  17. Disconnect the ball joint pinion from the control arm. Use tool 999 7062.
  18.  
  19. Install cap nut 7062-1 on the ball joint pinion.
  20.  
  21. Tighten the nut against the control arm.
  22.  
  23. Then turn back one turn to form a gap between the cap nut and the control arm.
  24.  
  25. Position the extractor on the control arm. Detach the ball joint from the control arm.

    Click image to see an enlarged view

    Fig. Using tool 999 7062 to extract ball joint

  26.  

To install:

  1. Install the steering knuckle on the trailing arm.
  2.  
  3. Install a new nut on the ball joint. Tighten to 59 ft. lbs. (80 Nm). Use a Torx wrench as counterhold.
    NOTE
    Make sure that the mating surfaces on the ball joint and link are clean.

  4.  
  5. Clean the splines on the halfshaft.
  6.  
  7. Turn the steering knuckle and bring the halfshaft into the hub.
  8.  
  9. Install halfshaft bolt and finger-tighten. Lubricate the bolt.
  10.  
  11. Install bolts retaining the spring strut in the steering knuckle. Use new bolts and nuts. Tighten to 78 ft. lbs. (105 Nm) and then angle-tighten 60°.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Ensure that the sensor seat in the steering knuckle is absolutely clean. Clean the ABS sensor with a soft brush.


    NOTE
    Ensure that the brake disc and wheel rim hub mating surfaces are clean.



    The anti-roll bar link to the spring strut. Use a new nut. Counterhold using a Torx wrench so that the boot is not damaged. Tighten to 37 ft. lbs. (50 Nm)
     
    The ABS sensor cable
     
    The ABS sensor onto the steering knuckle. Tighten the ABS sensor to 88 inch lbs. (10 Nm)
     



    The tie rod end onto the steering knuckle. Use a new nut. Tighten to 59 ft. lbs. (80 Nm)
     
    The brake disc. Tighten the brake disc locating pin to 88 inch lbs. (10 Nm)
     

  14.  
  15. Tighten the halfshaft bolt. Use a screwdriver as a counterhold on the brake disc. Tighten to 26 ft. lbs. (35 Nm), plus 120°.
  16.  
  17. Install the brake caliper. Use new bolts
  18.  
  19. Install the wheel. Tighten to 102 ft. lbs. (138 Nm).
  20.  

  1. Hoist vehicle and remove wheel.
  2.  
  3. Uncaulk drive shaft nut (1).
  4.  
  5. Depress foot brake pedal and hold it there. Remove drive shaft nut (1).
  6.  
  7. Remove caliper carrier bolts.

    Click image to see an enlarged view

    Fig. Identifying drive shaft nut

  8.  
  9. Remove caliper (1) with carrier.
    NOTE
    Hang removed caliper with a wire hook or the like (3) so as to prevent brake hose (4) from bending and twisting excessively or being pulled. Don-t operate brake pedal with pads removed.

  10.  
  11. Pull brake disc (2) off by using two 8 mm bolts.

    Click image to see an enlarged view

    Fig. Remove caliper and disc brake

  12.  
  13. Pull out wheel hub (1) with special tools (A) 09943-17912 and (B) 09942-15511.
    CAUTION
    When wheel hub is removed, replace wheel bearing with new one.



    Click image to see an enlarged view

    Fig. Remove the wheel hub

  14.  
  15. Disconnect tie-rod end (1) from steering knuckle (2) with special tool (A): 09913-65210.

    Click image to see an enlarged view

    Fig. Disconnect the tie rod end from the steering knuckle

  16.  
  17. Remove wheel speed sensor (1) from knuckle (if equipped with ABS).

    Click image to see an enlarged view

    Fig. Remove wheel speed sensor from steering knuckle

  18.  
  19. Loosen strut bracket nuts (1).
  20.  
  21. Remove ball joint bolt (3) and nut (4).
  22.  
  23. Remove strut bracket bolts from strut bracket and then steering knuckle (2).

    Click image to see an enlarged view

    Fig. Loosen strut bracket nuts then remove ball joint bolt, nut and strut bracket bolts from strut bracket then steering knuckle

  24.  

To install:

For installation, reverse removal procedure, noting the following instructions.



Using special tool (A) 09913-75520, drive wheel hub (1) into steering knuckle (2) and then install steering knuckle (2) to strut and lower ball joint.
 


CAUTION
Replace wheel bearing with new one whenever the wheel hub has been removed.



Click image to see an enlarged view

Fig. Drive wheel hub into steering knuckle and steering knuckle to strut and lower ball joint



Install ball joint bolt (1) and nut (2) from the direction as shown.
 
Tighten suspension arm ball joint nut (2) to 43.5 ft. lbs. (60 Nm).
 
Tighten strut bracket nuts (3) to 76.0 ft. lbs. (105 Nm).

Click image to see an enlarged view

Fig. Install ball joint bolt and nut and strut bracket nuts

 
Install ABS wheel speed sensor (1) (if equipped with ABS). Tighten the ABS wheel speed sensor mounting bolt (a) to 17.0 ft. lbs. (23 Nm).
 
Connect tie-rod end (1) to steering knuckle (2). Tighten castle nut (3) until holes for split pin (4) are aligned, but only within specified torque. Tighten tie rod end castle nut 32.5 ft. lbs. (45 Nm).
 
Install new split pin (4).

Click image to see an enlarged view

Fig. Connecting tie rod end to steering knuckle

 
Install brake caliper (3).
 
Tighten caliper carrier bolt to specified torque. Tighten caliper carrier bolt to 61.5 ft. lbs. (85 Nm)
 
Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to 127.0 ft. lbs. (175 Nm).
 


CAUTION
Never reuse drive shaft nut (1). Caulk drive shaft nut (1) as shown.


CAUTION
Be careful while caulking nut so that no crack will occur in caulked part of nut. Cracked nut must be replaced with new one.



Click image to see an enlarged view

Fig. Install brake caliper



Tighten the wheel nuts to 62 ft. lbs. (85 Nm).
 

 
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