Suzuki Esteem, Swift 1994-02

Overhaul

Print

Double Offset Joint



The Double Offset Joint (DOJ) type is identified by the outside shape of the differential side joint which has no dent.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the driveshaft.
  4.  
  5. Remove the boot band from the differential side joint.
  6.  
  7. Slide the boot towards the center of the shaft and remove the snapring from the outer race.
  8.  
  9. Remove the shaft from the outer race.
  10.  
  11. Use a rag to clean off the grease, then remove the circlip that retains the cage using snapring pliers.
  12.  
  13. Using a suitable puller, draw the cage away and remove the boot from the shaft.
  14.  
  15. Inspect all components for wear and/or damage and replace as necessary.

    Click image to see an enlarged view

    Fig. Remove the snapring from the outer race-DOJ type



    Click image to see an enlarged view

    Fig. Remove the circlip that retains the cage-DOJ type



    Click image to see an enlarged view

    Fig. Draw the cage away using a suitable puller-DOJ type

  16.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. Install the boot onto the shaft until its small diameter side fits to the shaft groove and attach it there with a boot band.
  4.  
  5. Using a pipe whose inner diameter is 0.906 in. (23mm) or more and outer diameter is 1.260 in. (32mm) or less, drive the cage into position. Install the cage using the smaller outside diameter side to the shaft end.
  6.  
  7. Install the circlip.
  8.  
  9. Apply grease to the entire surface of the cage.
  10.  
  11. Insert the cage into the outer race and fit the snapring into the groove of the outer race.
    NOTE
    Position the opening of the snapring so that it will not be lined up with a ball.

  12.  
  13. Apply grease to the inside of the outer race and fit the boot to the outer race.
  14.  
  15. After fitting the boot, insert a screwdriver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot equals atmospheric pressure
  16.  
  17. Fix the boot to the outer race with a boot band. Before tightening the band adjust the boot so that measurement D which is 8.10 in. (205.8mm) and measurement E which is 7.34 in. (186.4mm) are as shown in the accompanying illustration.
  18.  
  19. Install the driveshaft in the vehicle.

    Click image to see an enlarged view

    Fig. Adjust the boot so that measurements D and E are as illustrated-DOJ type

  20.  

The Double Offset Joint (DOJ) type is identified by the outside shape of the differential side joint which has no dent.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the driveshaft.
  4.  
  5. Remove the boot band from the differential side joint.
  6.  
  7. Slide the boot towards the center of the shaft and remove the snapring from the outer race.
  8.  
  9. Remove the shaft from the outer race.
  10.  
  11. Use a rag to clean off the grease, then remove the circlip that retains the cage using snapring pliers.
  12.  
  13. Using a suitable puller, draw the cage away and remove the boot from the shaft.
  14.  
  15. Inspect all components for wear and/or damage and replace as necessary.

    Click image to see an enlarged view

    Fig. Remove the snapring from the outer race-DOJ type



    Click image to see an enlarged view

    Fig. Remove the circlip that retains the cage-DOJ type



    Click image to see an enlarged view

    Fig. Draw the cage away using a suitable puller-DOJ type

  16.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. Install the boot onto the shaft until its small diameter side fits to the shaft groove and attach it there with a boot band.
  4.  
  5. Using a pipe whose inner diameter is 0.906 in. (23mm) or more and outer diameter is 1.260 in. (32mm) or less, drive the cage into position. Install the cage using the smaller outside diameter side to the shaft end.
  6.  
  7. Install the circlip.
  8.  
  9. Apply grease to the entire surface of the cage.
  10.  
  11. Insert the cage into the outer race and fit the snapring into the groove of the outer race.
    NOTE
    Position the opening of the snapring so that it will not be lined up with a ball.

  12.  
  13. Apply grease to the inside of the outer race and fit the boot to the outer race.
  14.  
  15. After fitting the boot, insert a screwdriver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot equals atmospheric pressure
  16.  
  17. Fix the boot to the outer race with a boot band. Before tightening the band adjust the boot so that measurement D which is 8.10 in. (205.8mm) and measurement E which is 7.34 in. (186.4mm) are as shown in the accompanying illustration.
  18.  
  19. Install the driveshaft in the vehicle.

    Click image to see an enlarged view

    Fig. Adjust the boot so that measurements D and E are as illustrated-DOJ type

  20.  

Tripod Joint



The Tripod joint type can be identified by the 3 dent lines on the outside of the differential side joint.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the driveshaft.
  4.  
  5. Remove the boot band and the Tripod joint housing.
  6.  
  7. Use a rag to clean off the grease, then remove the circlip using snapring pliers.
  8.  
  9. Remove the spider by using a suitable puller.
  10.  
  11. Remove the boot band and pull the differential side boot from the shaft.
  12.  
  13. Remove the dynamic damper band, then pull the damper through the shaft, if equipped.
  14.  
  15. Remove the boot bands from the wheel side joint boot and pull the boot through the shaft.
  16.  
  17. Inspect all components for wear and/or damage and replace as necessary.

    Click image to see an enlarged view

    Fig. Remove the circlip that retains the spider assembly-Tripod type

  18.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. On Swift models, perform the following:
    1. Apply grease to the wheel side joint. Use black grease in the tube included with the wheel side boot kit.
    2.  
    3. Install the wheel side boot on the shaft.
    4.  
    5. Fill the inside of the boot with grease and fasten the boot with a band.
    6.  
    7. Install the dynamic damper on the shaft, if equipped.
    8.  
    9. Install the differential side boot on the shaft.
    10.  
    11. Apply grease to the Tripod joint. Use the yellow grease in the tube included in the differential side joint kit.
    12.  
    13. Using a pipe whose inner diameter is 0.906 in. (23mm) or more and outer diameter is 1.260 in. (32mm) or less, drive the spider into position. Face the chamfered side inward and fasten it in place with the circlip.
    14.  
    15. Fill the boot with grease, then install the housing and joint it with the boot.
    16.  
    17. Fasten the boot bands.
    18.  

  4.  
  5. On Esteem models, perform the following:
    1. Apply grease to the wheel side joint. Use black grease in the tube included with the wheel side boot kit.
    2.  
    3. Install the wheel side boot on the shaft.
    4.  
    5. Fill the inside of the boot with grease.
    6.  
    7. Fit the boot band into the groove in the boot.
    8.  
    9. Tighten the boot band until its outer diameter is 3.05 in. (77.5mm).
    10.  
    11. Fold the boot band over the metal fixture.
    12.  
    13. Using a punch, caulk the center of the band folded over the fixture.

      Click image to see an enlarged view

      Fig. Using a punch, caulk the center of the band folded over the fixture-Esteem models

    14.  
    15. Cut the band about 0.28 in. (7mm) from the clip.
    16.  
    17. Clamp the band with the clip.
    18.  
    19. Fix the small diameter side of the boot band into the groove in the boot.
    20.  
    21. Tighten the boot band until its outer diameter is 1.14 in. (29mm).
    22.  
    23. Fold the boot band over the metal fixture.
    24.  
    25. Using a punch, caulk the center of the band folded over the fixture.
    26.  
    27. Install the dynamic damper on the right side driveshaft.
    28.  
    29. Install the differential side boot on the shaft.
    30.  
    31. Apply grease to the Tripod joint. Use the yellow grease in the tube included in the differential side joint kit.
    32.  
    33. Install the spider into position. Face the chamfered side inward and fasten it in place with the circlip.
    34.  
    35. Fill the boot with grease, then install the housing and joint it with the boot.
    36.  
    37. Adjust the boot so that the when measured from the tip of the driveshaft (wheels side), to the inner (small) band; the measurement is 8 in. (204mm).
    38.  

  6.  
  7. Insert a screwdriver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot equals atmospheric pressure
    1. Fasten the boot band so that diameter E which measures 3.11 in. (79mm) and diameter F which measures 1.14 in. (29mm) are correct. Refer to the accompanying illustration for the diameter locations.

      Click image to see an enlarged view

      Fig. Adjust the boot so that measurement D is correct-Esteem models equipped with a Tripod type joint



      Click image to see an enlarged view

      Fig. When tightening the bands, make sure that diameters E and F are correct-Esteem models equipped with a Tripod type joint

    2.  

  8.  
  9. Install the driveshaft.
  10.  

The Tripod joint type can be identified by the 3 dent lines on the outside of the differential side joint.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the driveshaft.
  4.  
  5. Remove the boot band and the Tripod joint housing.
  6.  
  7. Use a rag to clean off the grease, then remove the circlip using snapring pliers.
  8.  
  9. Remove the spider by using a suitable puller.
  10.  
  11. Remove the boot band and pull the differential side boot from the shaft.
  12.  
  13. Remove the dynamic damper band, then pull the damper through the shaft, if equipped.
  14.  
  15. Remove the boot bands from the wheel side joint boot and pull the boot through the shaft.
  16.  
  17. Inspect all components for wear and/or damage and replace as necessary.

    Click image to see an enlarged view

    Fig. Remove the circlip that retains the spider assembly-Tripod type

  18.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. On Swift models, perform the following:
    1. Apply grease to the wheel side joint. Use black grease in the tube included with the wheel side boot kit.
    2.  
    3. Install the wheel side boot on the shaft.
    4.  
    5. Fill the inside of the boot with grease and fasten the boot with a band.
    6.  
    7. Install the dynamic damper on the shaft, if equipped.
    8.  
    9. Install the differential side boot on the shaft.
    10.  
    11. Apply grease to the Tripod joint. Use the yellow grease in the tube included in the differential side joint kit.
    12.  
    13. Using a pipe whose inner diameter is 0.906 in. (23mm) or more and outer diameter is 1.260 in. (32mm) or less, drive the spider into position. Face the chamfered side inward and fasten it in place with the circlip.
    14.  
    15. Fill the boot with grease, then install the housing and joint it with the boot.
    16.  
    17. Fasten the boot bands.
    18.  

  4.  
  5. On Esteem models, perform the following:
    1. Apply grease to the wheel side joint. Use black grease in the tube included with the wheel side boot kit.
    2.  
    3. Install the wheel side boot on the shaft.
    4.  
    5. Fill the inside of the boot with grease.
    6.  
    7. Fit the boot band into the groove in the boot.
    8.  
    9. Tighten the boot band until its outer diameter is 3.05 in. (77.5mm).
    10.  
    11. Fold the boot band over the metal fixture.
    12.  
    13. Using a punch, caulk the center of the band folded over the fixture.

      Click image to see an enlarged view

      Fig. Using a punch, caulk the center of the band folded over the fixture-Esteem models

    14.  
    15. Cut the band about 0.28 in. (7mm) from the clip.
    16.  
    17. Clamp the band with the clip.
    18.  
    19. Fix the small diameter side of the boot band into the groove in the boot.
    20.  
    21. Tighten the boot band until its outer diameter is 1.14 in. (29mm).
    22.  
    23. Fold the boot band over the metal fixture.
    24.  
    25. Using a punch, caulk the center of the band folded over the fixture.
    26.  
    27. Install the dynamic damper on the right side driveshaft.
    28.  
    29. Install the differential side boot on the shaft.
    30.  
    31. Apply grease to the Tripod joint. Use the yellow grease in the tube included in the differential side joint kit.
    32.  
    33. Install the spider into position. Face the chamfered side inward and fasten it in place with the circlip.
    34.  
    35. Fill the boot with grease, then install the housing and joint it with the boot.
    36.  
    37. Adjust the boot so that the when measured from the tip of the driveshaft (wheels side), to the inner (small) band; the measurement is 8 in. (204mm).
    38.  

  6.  
  7. Insert a screwdriver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot equals atmospheric pressure
    1. Fasten the boot band so that diameter E which measures 3.11 in. (79mm) and diameter F which measures 1.14 in. (29mm) are correct. Refer to the accompanying illustration for the diameter locations.

      Click image to see an enlarged view

      Fig. Adjust the boot so that measurement D is correct-Esteem models equipped with a Tripod type joint



      Click image to see an enlarged view

      Fig. When tightening the bands, make sure that diameters E and F are correct-Esteem models equipped with a Tripod type joint

    2.  

  8.  
  9. Install the driveshaft.
  10.  

 
label.common.footer.alt.autozoneLogo