Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Axle Housing Assembly

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REMOVAL & INSTALLATION



Samurai Models

See Figure 1

  1. Loosen all of the front wheel lug nuts 1 / 2 turn. The front wheels should be left on the axle assembly so that the assembly may be rolled out from beneath the vehicle.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the vehicle with jackstands positioned beneath the frame rails.
  4.  



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Fig. Fig. 1: Exploded view of the front and rear axle housing assemblies

  1. Support the front axle assembly with two hydraulic floor jacks.
  2.  
  3. Drain the front axle assembly lubricant.
  4.  
  5. Detach and immediately plug the flexible rubber hoses from the front brake calipers, as described in Brakes .
  6.  
  7. If equipped, remove the front stabilizer bar, as described in Suspension & Steering .
  8.  
  9. Detach the drag rod from the right-hand side steering knuckle, as described in Brakes .
  10.  
  11. Remove the front driveshaft, as described earlier in this section.
  12.  
  13. Remove the front shock absorbers, as described in Suspension & Steering .
  14.  
  15. Remove the front leaf springs, as described in Suspension & Steering .
  16.  
  17. Carefully lower the front axle assembly with the floor jacks, ensuring that no cables, wires or other components will inhibit axle assembly removal.
  18.  
  19. Roll the front axle assembly out from beneath the vehicle.
  20.  
  21. The front axle assembly may now be disassembled.
  22.  

To install:
  1. Assemble the front axle assembly as necessary.
  2.  
  3. Roll the front axle assembly into position beneath the vehicle, then slowly raise the axle on two floor jacks.
  4.  
  5. Install the front leaf springs, shock absorbers, and driveshaft. Be sure that the driveshaft and differential flange matchmarks are properly aligned before bolting the two together.
  6.  
  7. Reattach the drag rod to the steering knuckle.
  8.  
  9. If applicable, install the front stabilizer bar.
  10.  
  11. Connect the flexible brake hoses to the front brake calipers.
  12.  
  13. Bleed the brake system, as described in Brakes .
  14.  
  15. Refill the front differential with lubricant, as described in General Information & Maintenance .
  16.  
  17. Lower the vehicle, then tighten the front wheel lug nuts to the specified value, as described in Suspension & Steering .
  18.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 2 through 16

  1. Apply the parking brake, block the rear wheels, then raise and safely support the vehicle with jackstands positioned beneath the frame rails.
  2.  
  3. Support the front axle assembly with two hydraulic floor jacks, or one transmission jack. If using the transmission jack, it is a good idea to secure the assembly to the jack with a strap or piece of rope.
  4.  



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Fig. Fig. 2: Exploded view of the front axle housing assembly



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Fig. Fig. 3: To remove the front axle/differential assembly, first matchmark the driveshaft and differential flange ...



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Fig. Fig. 4: ... then loosen the driveshaft attaching bolts



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Fig. Fig. 5: Separate the driveshaft from the flange ...



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Fig. Fig. 6: ... and suspend it with strong cord or wire



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Fig. Fig. 7: Support the axle assembly with a transmission jack-secure it to the jack with a strap or rope



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Fig. Fig. 8: Remove the four left-hand mounting bolts ...

  1. Drain the front axle assembly lubricant.
  2.  
  3. Detach the breather hose from the differential housing.
  4.  
  5. Detach the front driveshaft from the differential flange by removing the 4 mounting bolts, then suspend the end of the driveshaft with strong cord or wire.
  6.  



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Fig. Fig. 9: ... then matchmark the left halfshaft and differential housing for reinstallation



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Fig. Fig. 10: Loosen the left halfshaft attaching nuts and bolts, then separate the halfshaft from the differential housing



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Fig. Fig. 11: Loosen the two rear crossmember mounting bolts ...

  1. Loosen the four left mounting bracket bolts.
  2.  
  3. Mathcmark the left-hand halfshaft and differential case for reassembly, then remove the three left-hand halfshaft flange bolts to detach the left-hand halfshaft from the differential assembly.
  4.  
  5. Remove the two differential rear crossmember mount bolts, then remove the three mounting bolts on the right-hand of the housing.
  6.  
  7. Using two small prytools as levers, separate the right-hand halfshaft joint from the differential, then lower the differential assembly from the vehicle.
  8.  



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Fig. Fig. 12: ... then remove the right-hand mounting bolts



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Fig. Fig. 13: Use a prytool to disengage the right halfshaft from the differential housing ...



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Fig. Fig. 14: ... then lower the housing out of the vehicle



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Fig. Fig. 15: If necessary, the halfshaft oil seals can be removed from the housing while it is out of the vehicle ...

To install:
  1. Raise the differential assembly into position and reinstall the right-hand halfshaft in the assembly. Press the halfshaft into the differential until fully engaged.
  2.  
  3. Install the three right-hand differential assembly mounting bolts, then the two rear mounting bolts. Tighten the bolts until snug.
  4.  



Click image to see an enlarged view

Fig. Fig. 16: ... just ensure to use a mallet and the proper size driver to seat the new oil seals in place

  1. Reattach the left-hand halfshaft to the differential assembly and install the three attaching bolts. Tighten the halfshaft-to-differential flange bolts to 36-43 ft. lbs. (50-60 Nm).
  2.  
  3. Install the four left-hand differential mounting bolts. Tighten all of the differential assembly mounting bolts to 36-43 ft. lbs. (50-60 Nm).
  4.  
  5. Reattach the front driveshaft to the differential assembly, then tighten the mounting bolts to 36-43 ft. lbs. (50-60 Nm).
  6.  
  7. Reattach the breather hose to the differential housing.
  8.  
  9. Fill the front axle assembly with lubricant, as described in General Information & Maintenance .
  10.  
  11. Lower the vehicle and remove the wheel blocks.
  12.  

 
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