Suzuki Forenza, Reno 2003-06

Overhaul

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Cross Groove Joint Type



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the drive shaft.
  4.  
  5. Remove the large seal retaining clamp. Discard the clamp.
  6.  
  7. Remove the small seal retaining clamp. Discard the clamp.
  8.  
  9. Degrease the joint.

    Click image to see an enlarged view

    Fig. Spread the snap ring using snap ring pliers -Cross groove joint

  10.  
  11. Remove the shaft retaining ring using the snap ring pliers J-8059.

    Click image to see an enlarged view

    Fig. Remove/install the axle shaft from the joint assembly-Cross groove joint

  12.  
  13. Remove the axle shaft from the joint assembly.
  14.  
  15. Remove the seal from the joint assembly.
  16.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. Install a new small seal retaining clamp onto the seal. Do not crimp.
  4.  
  5. Install the seal onto the axle shaft.
  6.  
  7. Install the joint assembly onto the axle shaft.
  8.  
  9. Install the shaft retaining ring using the snap ring pliers J-8059.
  10.  
  11. Fill the joint assembly with 4.2-4.9 ounces (120-140g) of the recommended grease.
  12.  
  13. Repack the joint with 4.2-4.9 ounces (120-140g) of the recommended grease.
  14.  
  15. Install a new large seal retaining clamp.
  16.  
  17. Crimp the new large seal retaining clamp using the seal clamp pliers J-35566.
  18.  
  19. Crimp the new small retaining clamp using the seal clamp pliers J-35566.
  20.  

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 Section.
  2.  
  3. Remove the drive shaft.
  4.  
  5. Remove the large seal retaining clamp. Discard the clamp.
  6.  
  7. Remove the small seal retaining clamp. Discard the clamp.
  8.  
  9. Degrease the joint.
  10.  
  11. Spread the snap ring using snap ring pliers and remove the outer joint of the axle shaft.
  12.  
  13. Remove the seal from the joint assembly.
  14.  
  15. Inspect all components for wear and/or damage and replace as necessary.

    Click image to see an enlarged view

    Fig. Spread the snap ring using snap ring pliers -DOJ type

  16.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. Install the seal onto the axle shaft.
  4.  
  5. Spread the snap ring using snap ring pliers and install the outer joint the axle shaft.
  6.  
  7. Fill the joint seal with 4.2-4.9 ounces (120-140g) of the recommended grease.
  8.  
  9. Repack the joint with 4.2-4.9 ounces (120-140g) of the recommended grease.
  10.  
  11. Install a new large seal retaining clamp and a new small seal retaining clamp.

    Click image to see an enlarged view

    Fig. Crimp the new large seal retaining clamp using seal clamp pliers-DOJ type

  12.  
  13. Crimp the new small seal retaining clamp and the new large seal retaining clamp using the seal clamp pliers J-35566.
  14.  
  15. Install the drive axle shaft to the vehicle.
  16.  

Inner CV-Joint



  1. Remove the drive axle from the vehicle.
  2.  
  3. Remove the large seal retaining clamp. Discard the clamp.
  4.  
  5. Remove the small seal retaining clamp. Discard the clamp.

    Click image to see an enlarged view

    Fig. Axle and boot

  6.  
  7. Separate the joint housing from the boot.
  8.  
  9. Degrease the tripot assembly.
  10.  
  11. Remove the shaft retaining ring using the snap ring pliers.

    Click image to see an enlarged view

    Fig. Tripot and retaining ring

  12.  
  13. Remove the tripot and the tripot joint retaining ring from the axle shaft.
  14.  
  15. Remove the tripot joint seal from the axle shaft.
  16.  

To install:

  1. Install a new small seal retaining clamp onto the seal.
  2.  
  3. Install the seal onto the axle shaft.
  4.  
  5. Install the shaft retaining ring onto the axle shaft using the snap ring pliers.
  6.  
  7. Fill the tripot housing with 6.9-7.6 oz of the recommended grease. Repack the tripot with 6.9-7.6 oz of the recommended grease.
  8.  
  9. Install the boot to the joint housing.
  10.  
  11. Install a new large seal retaining clamp. Crimp the large seal retaining clamp using the seal clamp pliers.
  12.  
  13. Crimp the new small seal retaining clamp using the seal clamp pliers.
  14.  
  15. Install the drive axle shaft to the vehicle.
  16.  

Outer CV-Joint



  1. Remove the drive axle from the vehicle.
  2.  
  3. Remove the large seal retaining clamp. Discard the clamp.
  4.  
  5. Remove the small seal retaining clamp. Discard the clamp.
  6.  
  7. Degrease the joint.
  8.  
  9. Spread the snap ring using the snap ring pliers. and remove the outer joint the axle shaft.
  10.  
  11. Remove the seal from the joint assembly.
  12.  

To install:

  1. Install the seal onto the axle shaft.
  2.  
  3. Spread the snap ring using the snap ring pliers. and remove the outer joint the axle shaft.
  4.  
  5. Fill the joint seal with 4.2-4.9 oz of the recommended grease. Repack the joint with 4.2-4.9 oz of the recommended grease.
  6.  
  7. Install a new large seal retaining clamp and a new small seal retaining clamp.
  8.  
  9. Crimp the new small seal retaining clamp and the new large seal retaining clamp using the seal clamp pliers.
  10.  
  11. Install the drive axle shaft to the vehicle.
  12.  

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 Section.
  2.  
  3. Remove the drive shaft.
  4.  
  5. Remove the large seal retaining clamp. Discard the clamp.
  6.  
  7. Remove the small seal retaining clamp. Discard the clamp.
  8.  
  9. Separate the joint housing from the boot.
  10.  
  11. Degrease the joint.
  12.  
  13. Remove the shaft retaining ring using the snap ring pliers J-8059.
  14.  
  15. Remove the tripod and the tripod joint retaining ring from the axle shaft.
  16.  
  17. Remove the tripod joint seal from the axle shaft.
  18.  
  19. Inspect all components for wear and/or damage and replace as necessary.

    Click image to see an enlarged view

    Fig. Spread the snap ring using snap ring pliers -Tripod joint

  20.  

To install:

  1. Clean all components and allow them to completely dry.
  2.  
  3. Install a new small seal retaining clamp onto the seal.
  4.  
  5. Install the seal onto the axle shaft.
  6.  
  7. Install the shaft retaining ring onto the axle shaft using the snap ring pliers J-8059.
  8.  
  9. Fill the tripod housing with 6.9-7.6 ounces (195-215g) of the recommended grease.
  10.  
  11. Repack the tripod with 6.9-7.6 ounces (195-215g) of the recommended grease.
  12.  
  13. Install the boot to the joint housing.
  14.  
  15. Install a new large seal retaining clamp. Crimp the large seal retaining clamp using the seal clamp pliers J-35566.

    Click image to see an enlarged view

    Fig. Crimp the new seal retaining clamps using seal clamp pliers-Tripod joint

  16.  
  17. Crimp the new small seal retaining clamp using the seal clamp pliers J-35566.
  18.  
  19. Install the drive shaft to the vehicle.
  20.  

 
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