Suzuki Aerio, Verona 2002-06

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove drive shaft nut and washer.
  6.  
  7. Raise and safely support the front of the vehicle securely on jackstands.
  8.  
  9. Remove wheel.
  10.  
  11. Drain transaxle oil.
  12.  
  13. Remove tie rod end cotter pin and castle nut.
  14.  
  15. Disconnect tie rod end from steering knuckle by using special tool 09913-65210.
  16.  
  17. Using plastic hammer, drive out drive shaft joint so as to release snap ring fitting of joint spline at center shaft.
  18.  
  19. Disconnect front suspension control arm ball stud from steering knuckle after removing ball stud bolt and nut.
  20.  
  21. Remove drive shaft assembly.
    NOTE
    To prevent damage of boots, be careful not to contact them with other parts when removing drive shaft assembly.

  22.  
  23. Remove center shaft support bolts and remove center shaft support with center shaft from differential side gear shaft (if equipped).
  24.  

To install:

  1. Install drive shaft assembly by reversing removal procedure noting the following points:


    1. Tighten each bolt and nut to the specified torque.

      Transaxle oil filler/level and drain plug (for M/T): 15.5 ft. lbs. (21 Nm)
       
      Transaxle fluid drain plug (for A/T): 29 ft. lbs. (40 Nm)
       
      Ball stud bolt: 43.5 ft. lbs. (60 Nm)
       
      Tie rod end castle nut: 25.5-40 ft. lbs. (35-55 Nm)
       
      New drive shaft nut: 127 ft. lbs. (175 Nm)
       
      Wheel nut: 61.5 ft. lbs. (85 Nm)
       
      Center shaft support bolt: 40 ft. lbs. (55 Nm)
       

    2.  

  2.  
  3. Apply sealant to drain plug and filler/level plug for manual transaxle.
  4.  
  5. Fill transaxle with the correct type and amount of oil.
  6.  
  7. Connect the negative battery cable
  8.  

Automatic Transaxle



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain transaxle oil.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Spindle nut on halfaxle
     

  6.  
  7. Remove stub of halfshaft from hub.
    NOTE
    If necessary, use a screwdriver in brake disc vents as a counterhold and tap the end of the halfshaft with a plastic hammer or brass drift until halfshaft moves into the hub approximately 3 / 4 -1 inch (20-25mm).

  8.  
  9. Remove lower ball joint from the knuckle. Refer to Lower Ball Joint removal and installation.
  10.  
  11. Remove halfshaft from the hub.
  12.  
  13. If removing the left side halfshaft:
    1. Use prybar 999 5462 B, or suitable prybar, to pry the inner joint out of the transaxle.
    2.  

  14.  
  15. If removing the right side halfshaft:
    1. 5- & 8-Cylinder transaxles: Remove the bearing cap for the halfshaft, hold down the spring strut, and pull out the halfshaft.
    2.  
    3. 6-Cylinder tansaxles: Use prybar 999 5462 B, or suitable prybar, to pry the inner joint out of the transaxle.
    4.  

  16.  
  17. Remove halfshaft.
  18.  

To install:


NOTE
Use new circlips, split pins, and self-locking nuts for assembly.

  1. Apply gear oil on the halfshaft splines.
  2.  
  3. When installing the halfshaft, set the opening side of the circlip so it faces downward.
  4.  
  5. Install the inner joint so that the circlip is felt to seat in the retaining groove.
  6.  
  7. Lubricate the halfshaft splines for the wheel hub with a small amount of oil.
  8.  
  9. Hold down the control arm as when removing. Align the halfshaft in the hub.
  10.  
  11. Align the ball joint in the control arm.
  12.  
  13. Install a new lock nut on the ball joint. Tighten to 59 ft. lbs. (80 Nm).
    NOTE
    Counterhold the end of the ball joint while tightening so that the boot does not twist. Use a Torx wrench.

  14.  
  15. Install a new bolt for the halfshaft/wheel hub. Tighten to 26 ft. lbs. (35 Nm), plus 120°.
  16.  
  17. Install front wheel and tighten lug nuts to 102 ft. lbs. (138 Nm).
  18.  
  19. Check and/or adjust the wheel alignment.
  20.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the front of the vehicle securely on jackstands.
  6.  
  7. Remove wheel.
  8.  
  9. Remove drive shaft nut and washer.
  10.  
  11. Disconnect front suspension control arm ball stud from steering knuckle after removing ball stud bolt and nut.
    NOTE
    Use only a tool made specifically for separating the lower ball joint. Failure to use the correct tool may cause damage to the ball joint and the seal.

  12.  
  13. Remove tie rod end nut.
  14.  
  15. Disconnect tie rod end from steering knuckle by using ball joint separator KM-507-B.
    NOTE
    Use only a tool made specifically for separating the tie rod from the steering knuckle. Failure to use the correct tool may cause damage to the knuckle/strut assembly.

  16.  
  17. Remove the drive axle from the intermediate axle shaft using the axle shaft remover KM-460-A.
  18.  
  19. Remove the intermediate axle shaft mounting bolts and the shaft from the transaxle.
    NOTE
    Support the unfastened end of the drive axle. Do not allow the drive axle to dangle freely from the transaxle for any length of time after it has been removed from the wheel hub. Place a drain pan below the transaxle to catch the escaping fluid. Cap the transaxle drive opening after the drive axle has been removed to keep the fluid in and any contamination out.

  20.  

To install:

  1. Clean the hub seal and the transaxle seal. Be careful to not damage the seals.
  2.  
  3. Install the intermediate axle shaft into the transaxle. Tighten the intermediate axle shaft mounting bolts to 38 ft. lbs. (52 Nm).
  4.  
  5. Install the drive axle into the intermediate axle shaft.
  6.  
  7. Install the wheel hub onto the axle shaft.
  8.  
  9. Mount the steering knuckle onto the lower ball joint.
  10.  
  11. Install the tie rod into the knuckle/strut and install the tie rod nut. Tighten the tie rod nut to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the lower ball joint bolt and nut and tighten to 77 ft. lbs. (105 Nm).
  14.  
  15. Loosely install the washer and a new axle shaft caulking nut. Always use a new nut.
  16.  
  17. Tighten the new axle shaft caulking nut to 236 ft. lbs. (320 Nm).
  18.  
  19. Peen the new caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
  20.  
  21. Install the wheels. Loosely install the nuts.
  22.  
  23. Lower the vehicle to the floor and tighten the wheel nuts to 74 ft. lbs. (100 Nm).
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Refill the transaxle fluid to the proper level.
  28.  

Front



Automatic Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove drive shaft nut and washer.
  6.  
  7. Raise and safely support the front of the vehicle securely on jackstands.
  8.  
  9. Remove wheel.
  10.  
  11. Drain transaxle oil.
  12.  
  13. Remove tie rod end cotter pin and castle nut.
  14.  
  15. Disconnect tie rod end from steering knuckle by using special tool 09913-65210.
  16.  
  17. Using plastic hammer, drive out drive shaft joint so as to release snap ring fitting of joint spline at center shaft.
  18.  
  19. Disconnect front suspension control arm ball stud from steering knuckle after removing ball stud bolt and nut.
  20.  
  21. Remove drive shaft assembly.
    NOTE
    To prevent damage of boots, be careful not to contact them with other parts when removing drive shaft assembly.

  22.  
  23. Remove center shaft support bolts and remove center shaft support with center shaft from differential side gear shaft (if equipped).
  24.  

To install:

  1. Install drive shaft assembly by reversing removal procedure noting the following points:


    1. Tighten each bolt and nut to the specified torque.

      Transaxle oil filler/level and drain plug (for M/T): 15.5 ft. lbs. (21 Nm)
       
      Transaxle fluid drain plug (for A/T): 29 ft. lbs. (40 Nm)
       
      Ball stud bolt: 43.5 ft. lbs. (60 Nm)
       
      Tie rod end castle nut: 25.5-40 ft. lbs. (35-55 Nm)
       
      New drive shaft nut: 127 ft. lbs. (175 Nm)
       
      Wheel nut: 61.5 ft. lbs. (85 Nm)
       
      Center shaft support bolt: 40 ft. lbs. (55 Nm)
       

    2.  

  2.  
  3. Apply sealant to drain plug and filler/level plug for manual transaxle.
  4.  
  5. Fill transaxle with the correct type and amount of oil.
  6.  
  7. Connect the negative battery cable.
  8.  

Manual Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove drive shaft nut and washer.
  6.  
  7. Raise and safely support the front of the vehicle securely on jackstands.
  8.  
  9. Remove wheel.
  10.  
  11. Drain transaxle oil.
  12.  
  13. Remove tie rod end cotter pin and castle nut.
  14.  
  15. Disconnect tie rod end from steering knuckle by using special tool 09913-65210.
  16.  
  17. Using plastic hammer, drive out drive shaft joint so as to release snap ring fitting of joint spline at center shaft.
  18.  
  19. Disconnect front suspension control arm ball stud from steering knuckle after removing ball stud bolt and nut.
  20.  
  21. Remove drive shaft assembly.
    NOTE
    To prevent damage of boots, be careful not to contact them with other parts when removing drive shaft assembly.

  22.  
  23. Remove center shaft support bolts and remove center shaft support with center shaft from differential side gear shaft (if equipped).
  24.  

To install:

  1. Install drive shaft assembly by reversing removal procedure noting the following points:


    1. Tighten each bolt and nut to the specified torque.

      Transaxle oil filler/level and drain plug (for M/T): 15.5 ft. lbs. (21 Nm)
       
      Transaxle fluid drain plug (for A/T): 29 ft. lbs. (40 Nm)
       
      Ball stud bolt: 43.5 ft. lbs. (60 Nm)
       
      Tie rod end castle nut: 25.5-40 ft. lbs. (35-55 Nm)
       
      New drive shaft nut: 127 ft. lbs. (175 Nm)
       
      Wheel nut: 61.5 ft. lbs. (85 Nm)
       
      Center shaft support bolt: 40 ft. lbs. (55 Nm)
       

    2.  

  2.  
  3. Apply sealant to drain plug and filler/level plug for manual transaxle.
  4.  
  5. Fill transaxle with the correct type and amount of oil.
  6.  
  7. Connect the negative battery cable.
  8.  

Manual Transaxle



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the front of the vehicle securely on jackstands.
  6.  
  7. Remove wheel.
  8.  
  9. Remove drive shaft nut and washer.
  10.  
  11. Disconnect front suspension control arm ball stud from steering knuckle after removing ball stud bolt and nut.
    NOTE
    Use only a tool made specifically for separating the lower ball joint. Failure to use the correct tool may cause damage to the ball joint and the seal.

  12.  
  13. Remove tie rod end nut.
  14.  
  15. Disconnect tie rod end from steering knuckle by using ball joint separator KM-507-B.
    NOTE
    Use only a tool made specifically for separating the tie rod from the steering knuckle. Failure to use the correct tool may cause damage to the knuckle/strut assembly.

  16.  
  17. Remove the drive axle from the intermediate axle shaft using the axle shaft remover KM-460-A.
  18.  
  19. Remove the intermediate axle shaft mounting bolts and the shaft from the transaxle.
    NOTE
    Support the unfastened end of the drive axle. Do not allow the drive axle to dangle freely from the transaxle for any length of time after it has been removed from the wheel hub. Place a drain pan below the transaxle to catch the escaping fluid. Cap the transaxle drive opening after the drive axle has been removed to keep the fluid in and any contamination out.

  20.  

To install:

  1. Clean the hub seal and the transaxle seal. Be careful to not damage the seals.
  2.  
  3. Install the intermediate axle shaft into the transaxle. Tighten the intermediate axle shaft mounting bolts to 38 ft. lbs. (52 Nm).
  4.  
  5. Install the drive axle into the intermediate axle shaft.
  6.  
  7. Install the wheel hub onto the axle shaft.
  8.  
  9. Mount the steering knuckle onto the lower ball joint.
  10.  
  11. Install the tie rod into the knuckle/strut and install the tie rod nut. Tighten the tie rod nut to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the lower ball joint bolt and nut and tighten to 77 ft. lbs. (105 Nm).
  14.  
  15. Loosely install the washer and a new axle shaft caulking nut. Always use a new nut.
  16.  
  17. Tighten the new axle shaft caulking nut to 236 ft. lbs. (320 Nm).
  18.  
  19. Peen the new caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
  20.  
  21. Install the wheels. Loosely install the nuts.
  22.  
  23. Lower the vehicle to the floor and tighten the wheel nuts to 74 ft. lbs. (100 Nm).
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Refill the transaxle fluid to the proper level.
  28.  

Rear



Automatic Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove drive shaft nut and washer.
  6.  
  7. Raise and safely support the rear of the vehicle securely on jackstands.
  8.  
  9. Remove wheel.
  10.  
  11. Drain rear differential oil.

    Click image to see an enlarged view

    Fig. Parking brake wire mounting bolt (1), rear control rod outer bolts (2) and rear trailing rod rear bolt (3)-Aerio with AWD

  12.  
  13. Remove parking brake wire mounting bolt (1), rear control rod outer bolts (2) and rear trailing rod rear bolt (3).

    Click image to see an enlarged view

    Fig. Pull out drive shaft from rear differential gear case by using tire lever with a used clamp-Aerio with AWD

  14.  
  15. Install used clamp (2) to differential side joint (1) and pull out drive shaft from rear differential gear case by using tire lever (3).
  16.  
  17. Remove drive shaft.
  18.  

To install:


WARNING
Protect oil seals and boots from any damage, preventing them form unnecessary contact while 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.

  1. Clean rear wheel bearing oil seal and then apply grease. Replace it if required.
  2.  
  3. Install drive shaft assembly by reversing removal procedure noting the following points:


    1. Tighten each bolt and nut to the specified torque.

      Rear control rod outer bolt: 68.5 ft. lbs. (95 Nm)
       
      Rear trailing rod rear bolt: 68.5 ft. lbs. (95 Nm)
       
      New drive shaft nut: 127 ft. lbs. (175 Nm)
       

    2.  

  4.  
  5. Clean rear wheel bearing oil seal and then apply grease. Replace it if required.
  6.  
  7. Apply sealant to drain plug for rear differential gear case.
  8.  
  9. Fill rear differential gear case with the correct type and amount of oil.
  10.  
  11. Connect the negative battery cable.
  12.  

Manual Transaxle
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove drive shaft nut and washer.
  6.  
  7. Raise and safely support the rear of the vehicle securely on jackstands.
  8.  
  9. Remove wheel.
  10.  
  11. Drain rear differential oil.

    Click image to see an enlarged view

    Fig. Parking brake wire mounting bolt (1), rear control rod outer bolts (2) and rear trailing rod rear bolt (3)-Aerio with AWD

  12.  
  13. Remove parking brake wire mounting bolt (1), rear control rod outer bolts (2) and rear trailing rod rear bolt (3).

    Click image to see an enlarged view

    Fig. Pull out drive shaft from rear differential gear case by using tire lever with a used clamp-Aerio with AWD

  14.  
  15. Install used clamp (2) to differential side joint (1) and pull out drive shaft from rear differential gear case by using tire lever (3).
  16.  
  17. Remove drive shaft.
  18.  

To install:


WARNING
Protect oil seals and boots from any damage, preventing them form unnecessary contact while 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.

  1. Clean rear wheel bearing oil seal and then apply grease. Replace it if required.
  2.  
  3. Install drive shaft assembly by reversing removal procedure noting the following points:


    1. Tighten each bolt and nut to the specified torque.

      Rear control rod outer bolt: 68.5 ft. lbs. (95 Nm)
       
      Rear trailing rod rear bolt: 68.5 ft. lbs. (95 Nm)
       
      New drive shaft nut: 127 ft. lbs. (175 Nm)
       

    2.  

  4.  
  5. Clean rear wheel bearing oil seal and then apply grease. Replace it if required.
  6.  
  7. Apply sealant to drain plug for rear differential gear case.
  8.  
  9. Fill rear differential gear case with the correct type and amount of oil.
  10.  
  11. Connect the negative battery cable.
  12.  

 
label.common.footer.alt.autozoneLogo