Suzuki Forenza, Reno 2003-06

Removal & Installation

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Automatic 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 vehicle.
  6.  
  7. Remove wheel.
  8.  
  9. Remove drive shaft nut and washer. Discard nut.
  10.  
  11. Disconnect front suspension control arm ball stud from steering knuckle after removing pinch 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. If equipped with automatic transaxle, perform the following:


    1. Remove the damping block connection nut and bolt.
    2.  
    3. Remove the rear mounting bracket bolts and the bracket.
    4.  

  18.  
  19. Push the drive shaft from the wheel hub.
  20.  
  21. Remove drive shaft assembly from the transaxle using axle shaft removal tool DW340-110 (A/T), or KM-460-A (M/T).
    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.

  22.  

To install:

  1. Clean the hub seal and the transaxle seal. Be careful to not damage the seals.
  2.  
  3. Install the drive shaft into the transaxle.
  4.  
  5. Install the wheel hub onto the axle shaft.
  6.  
  7. If equipped with automatic transaxle, perform the following:


    1. Install the rear mounting bracket bolts and the bracket and tighten to 45 ft. lbs. (62 Nm).
    2.  
    3. Install the damping block connection nut and bolt and tighten to 50 ft. lbs. (68 Nm).
    4.  

  8.  
  9. Install the tie rod into the knuckle/strut and install the tie rod nut. Tighten the tie rod nut to 41 ft. lbs. (55 Nm).
  10.  
  11. Install the lower ball joint pinch bolt and nut and tighten to 44 ft. lbs. (60 Nm).
  12.  
  13. Loosely install the washer and a new axle shaft caulking nut. Always use a new nut.
  14.  
  15. Install the wheels. Loosely install the nuts.
  16.  
  17. Lower the vehicle to the floor and tighten the wheel nuts to 74 ft. lbs. (100 Nm).
  18.  
  19. Tighten the new axle shaft caulking nut to 221 ft. lbs. (300 Nm).
  20.  
  21. Peen the new caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
  22.  
  23. Refill the transaxle fluid to the proper level.
  24.  
  25. Connect the negative battery cable.
  26.  

Manual Transaxle



  1. Raise and suitably support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the axle shaft caulking nut. Discard the nut.

    Click image to see an enlarged view

    Fig. Axle shaft caulking nut

  6.  
  7. Remove the lower ball joint pinch bolt and nut.
  8.  
  9. Separate the steering knuckle from the lower ball joint.
  10.  
  11. Remove the tie rod nut.
  12.  
  13. Separate the tie rod end.

    Click image to see an enlarged view

    Fig. Lower ball joint pinch nut and related parts

  14.  
  15. Push the drive axle shaft from the wheel hub.
  16.  
  17. Remove the drive axle from the transaxle.
  18.  

To install:

  1. Clean the hub seal and the transaxle seal.
  2.  
  3. Install the drive axle into the transaxle.
  4.  
  5. Install the wheel hub onto the axle shaft.
  6.  
  7. Install the tie rod into the knuckle/strut and install the tie rod nut.
  8.  
  9. Tighten the tie rod nut to 41 ft lbs. (55 Nm)
  10.  
  11. Install the lower ball joint pinch bolt and nut.
  12.  
  13. Tighten the lower ball joint pinch bolt and nut to 44 ft lbs. (60 Nm)
  14.  
  15. Loosely install a new axle shaft caulking nut.
    NOTE
    Always use a new nut.

  16.  
  17. Install the wheels. Loosely install the nuts.
  18.  
  19. Lower the vehicle to the floor.
  20.  
  21. Tighten the wheel nuts to 74 ft lbs. (100 Nm)
  22.  
  23. Tighten the axle shaft caulking nut to 221 ft lbs. (300 Nm)
  24.  
  25. Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub.
  26.  
  27. Refill the transaxle fluid to the proper level.
  28.  

 
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