Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Locking Hubs

Print

REMOVAL & INSTALLATION



Samurai Models

See Figure 1

  1. Raise and safely support the vehicle. Remove the front wheels.
  2.  
  3. Remove the caliper mounting bolts and move the caliper out of position with the brake line attached.
  4.  


WARNING
Do not allow the caliper to hang on the brake hose, otherwise the flexible rubber hose may be damaged. Support it by the mounting bracket.

  1. Install 2 (8mm) bolts into the threaded holes and tighten evenly. This will remove the rotor from the hub assembly.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Cross-sectional view of the locking hub assembly used by Samurai models

  1. Thread a bolt into the axle shaft and pull the axle shaft out towards you. Remove the snapring.
  2.  
  3. Remove the locking hub body assembly.
  4.  

To install:
  1. Install a new gasket onto the locking hub assembly.
  2.  
  3. Install the locking hub body assembly to the wheel hub flange and tighten the hub body bolts to 212 inch lbs. (24 Nm).
  4.  
  5. Thread a bolt into the axle shaft and pull the axle shaft out towards you. Install the snapring and remove the bolt from the axle shaft.
  6.  
  7. Install a new gasket in the manual locking hub cover.
  8.  
  9. Before installing the locking hub cover, make sure of the following:

    The selector knob is in the FREE position.
     
    The clutch should be lifted (retracted) towards the cover. The clutch must be positioned properly to ensure proper hub operations.
     
    The gasket is centered and installed correctly.
     

  10.  
  11. Install the locking hub cover and tighten the bolts to 115 inch lbs. (13 Nm).
  12.  

The mark on the hub knob must be facing the FREE position.

  1. Check that the hub assembly is working correctly. If there are problems with the operation, Remove the hub cover and repeat steps 9-12.
  2.  
  3. Install the brake rotor.
  4.  
  5. Place the brake caliper into position and install the caliper mounting bolts.
  6.  
  7. If removed, reconnect the locking hub assembly and install the front wheels.
  8.  
  9. Lower the vehicle.
  10.  
  11. Pump the brake pedal several times to seat the front brake pads. Road test the vehicle and verify proper operation.
  12.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

AUTOMATIC LOCKING HUBS
  1. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. Unscrew the automatic hub cover and remove the cover and O-ring.
  4.  
  5. Remove the hub assembly mounting bolts and remove the hub assembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: To remove the automatic locking hub, loosen the cover-an oil filter wrench does a good job



Click image to see an enlarged view

Fig. Fig. 3: Remove the cover from the automatic locking hub assembly ...



Click image to see an enlarged view

Fig. Fig. 4: ... then loosen the six mounting screws ...



Click image to see an enlarged view

Fig. Fig. 5: ... and pull the hub assembly off of the end of the halfshaft



Click image to see an enlarged view

Fig. Fig. 6: Once the hub is removed, the axle shaft retaining snapring (A) and bearing lockwasher (B) can be accessed

To install:
  1. Install a new O-ring on the hub assembly.
  2.  
  3. Install the hub assembly onto the wheel flange. Make sure the tab on the hub fits into the notch on the spindle.
  4.  
  5. Install the six mounting bolts and tighten to 221 inch lbs. (25 Nm).
  6.  
  7. Install a new O-ring on the hub cover.
  8.  
  9. Install the hub cover.
  10.  
  11. Lower the vehicle and remove the wheel blocks.
  12.  

MANUAL LOCKING HUBS
  1. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle.
  2.  
  3. Remove the six manual hub cover mounting bolts and remove the manual hub cover and gasket.
  4.  
  5. Remove the six manual hub mounting bolts.
  6.  
  7. Remove the manual hub and O-ring.
  8.  

To install:
  1. Install a new O-ring on the manual hub body.
  2.  
  3. Install the manual hub onto the wheel flange and install the six mounting bolts. Tighten the mounting bolts to 159 inch lbs. (25 Nm).
  4.  
  5. Install a new gasket on the manual hub cover.
  6.  
  7. Install the hub cover on the hub. The lever must be in the FREE position with the clutch pulled out toward the cover.
  8.  
  9. Install the six mounting bolts. Tighten the bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Lower the vehicle and remove the wheel blocks.
  12.  

 
label.common.footer.alt.autozoneLogo