Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

U-Joints

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DISASSEMBLY & ASSEMBLY



See Figures 1, 2 and 3

  1. Remove the driveshaft from the vehicle.
  2.  
  3. Remove the two snaprings from the pinion flange.
  4.  
  5. Use a 18mm socket as a driver and a 24mm socket as a cup. Place the driveshaft in a soft jaw vice with the 18mm socket against one of the bearing caps and the 24mm positioned so the bearing cap will slide into the socket. Compress the vice until the bearing cap has moved out 3-4mm.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the typical universal joint



Click image to see an enlarged view

Fig. Fig. 2: To disassemble the U-joint, remove the two snaprings from the universal joint pinion flange

  1. Remove the driveshaft and sockets from the vice. Reposition the driveshaft so the vice jaws can be clamped down on the exposed portion of the bearing cap. With the cap clamped snugly, tap upward on the driveshaft until the cap comes free.
  2.  
  3. Using the 18mm socket and a hammer remove the other bearing cap by driving it out of the pinion flange.
  4.  
  5. Remove the pinion flange.
  6.  
  7. Remove the two snaprings from the driveshaft yoke.
  8.  
  9. Use a 18mm socket as a driver and a 24mm socket as a cup. Place the driveshaft in a soft jaw vice with the 18mm socket against one of the bearing caps and the 24mm positioned so the bearing cap will slide into the socket. Compress the vice until the bearing cap has moved out 3-4mm.
  10.  
  11. Remove the driveshaft and sockets from the vice. Reposition the driveshaft so the vice jaws can be clamped down on the exposed portion of the bearing cap. With the cap clamped snugly, tap upward on the driveshaft until the cap comes free.
  12.  
  13. Using the 18mm socket and a hammer remove the other bearing cap by driving it out of the driveshaft.
  14.  
  15. Remove the U-joint.
  16.  

To assemble:
  1. Install the U-joint into the driveshaft yoke.
  2.  


WARNING
DO NOT force the bearing caps into place. If the U-joint will not move freely, one of the bearing cap needle bearings may have become unseated. Remove the bearing caps and check needle bearing position.

  1. Install one bearing cap into the driveshaft yoke. Fit the end of the U-joint into the bearing cap and using a hammer lightly tap the cap until it is flush with the yoke. Using an 18mm socket, tap the bearing cap down until the snapring groove is visible.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Use a hammer to tap the bearing cap until it is flush with the driveshaft yoke

  1. Install the second bearing cap and position the U-joint so the it is part way into each bearing cap. Lightly tap the second bearing cap into place. Using an 18mm socket tap the U-joint down until the snapring groove is visible.
  2.  
  3. Install the two snaprings.
  4.  
  5. Verify the U-joint moves freely.
  6.  
  7. Install the pinion flange over the U-joint.
  8.  
  9. Install one bearing cap into the pinion flange yoke. Fit the end of the U-joint into the bearing cap and using a hammer lightly tap the cap until it is flush with the yoke. Using an 18mm socket, tap the bearing cap down until the snapring groove is visible.
  10.  
  11. Install the second bearing cap and position the U-joint so the it is part way into each bearing cap. Lightly tap the second bearing cap into place. Using an 18mm socket tap the U-joint down until the snapring groove is visible.
  12.  
  13. Install the two snaprings.
  14.  
  15. Verify the U-joint moves freely.
  16.  
  17. Lubricate the U-joint at the grease fitting and install the driveshaft in the vehicle.
  18.  

 
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