Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Driveshafts

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REMOVAL & INSTALLATION



Samurai Models

See Figures 1 and 2

The 4WD Samurai uses three separate driveshafts, the shafts are designated as No. 1, No. 2, and No. 3: the No. 1 shaft connects the transmission to the transfer case, the No. 2 shaft connects the transfer case to the front differential, the No. 3 shaft connects the transfer case to the rear differential.

The 2WD vehicle uses two separate driveshafts the No. 1 and No. 3 driveshafts. The driveshafts are used in the 2WD vehicles the same way as they are used in the 4WD vehicles.



Click image to see an enlarged view

Fig. Fig. 1: The Samurai uses three driveshafts-driveshaft No. 1 connects the transmission to the transfer case, No. 2 connects the transfer to the front differential, No. 3 connects the transfer to the rear differential

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Matchmark the driveshafts to the yokes on the transfer case, or transmission, and the differential.
  4.  
  5. Support the driveshaft and remove the attaching bolts.
  6.  
  7. Remove the driveshaft from the vehicle.
  8.  

The transmission side end of the No. 1 shaft does not have a flange piece; the end is splined and slides onto the output shaft inside the extension case. To remove the shaft, after detaching the transfer case end, just pull the shaft out of the extension case. When removing the No. 1 shaft, the transmission fluid will not leak if the front and the rear of the vehicle are raised evenly and the transmission fluid is filled to specification. If the vehicle is raised unevenly or the fluid is above specification, drain the transmission fluid prior to removing the No. 1 shaft.

To install:
  1. The No. 2 and No. 3 shafts are equipped with slip joints on the shafts so that the driveshaft can expand (lengthen) or contract (shorten) itself. Pull the driveshaft apart and liberally fill the driveshaft splines with chassis grease. When reassembling the driveshaft, align the matchmarks on the splines and the shaft to prevent noise or vibration. Verify that the rubber boot is pulled over and is protecting the driveshaft splines.
  2.  



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Fig. Fig. 2: Apply multi-purpose grease to the slip joint splines, then assemble the driveshaft halves

  1. Install the driveshaft, by aligning the matchmarks made during disassembly.
  2.  
  3. Install and tighten the mounting bolts to 37-43 ft. lbs. (50-60 Nm).
  4.  
  5. Lubricate the driveshaft U-joints at the grease fittings and lower the vehicle.
  6.  
  7. If fluid was drained (or leaked), refill the transmission to the proper level with the proper lubricant.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: To remove the typical driveshaft, matchmark the driveshaft to the differential flange ...



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Fig. Fig. 4: ... then loosen the attaching nuts and bolts



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Fig. Fig. 5: It may be necessary to use a plastic mallet to break the driveshaft free of the differential flange



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Fig. Fig. 6: Lower the end of the driveshaft ...



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Fig. Fig. 7: ... then slide the other end out of the transmission/transfer case-some models use another flange on this end as well

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figure 3

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Matchmark the driveshaft(s) yokes to the flanges on the transfer case, or transmission, and the differential.
  4.  
  5. On 4WD models, drain the transfer case oil.
  6.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the front and rear driveshaft assemblies used on Sidekick, Tracker, Sidekick Sport and X-90 models

  1. Support the driveshaft and remove the attaching nuts and bolts.
  2.  
  3. Remove the driveshaft from the vehicle.
  4.  

To install:
  1. Install the driveshaft, by aligning the matchmarks on the yoke with those on the flanges.
  2.  
  3. Tighten the driveshaft yoke-to-flange bolts and nuts to 40 ft. lbs. (55 Nm).
  4.  
  5. On 4WD models, refill the transfer case. Apply Loctite® pipe sealant to the threads of the oil lever filler plug, then install the plug in the transfer case.
  6.  
  7. Safely lower the vehicle.
  8.  

 
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