Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Front Wheel Bearings and Hubs

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ADJUSTMENT



Samurai Models

See Figure 1

Wheel bearing starting preload should be 2.2-6.6 lbs. (13 kg).

  1. Raise the front end of the vehicle, and remove the front wheels.
  2.  
  3. Remove the wheel bearing locknut and lockwasher.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Check the wheel bearing starting preload using a spring scale as shown

  1. Tighten the bearing nut to 57 ft. lbs. (80 Nm) while spinning the hub by hand.
  2.  
  3. Loosen the nut to completely, and then tighten it to the proper torque of 7-10 ft. lbs. (10-15 Nm). This will give the proper bearing preload.
  4.  
  5. Insert the lockwasher after adjustment, and tighten the locknut to 10-65 ft. lbs. (60-90 Nm). Bend a part of the lockwasher toward the bearing nut (on body side), and another toward the locknut (outside); this will lock the two nuts.
  6.  
  7. Recheck the bearing starting preload, making sure it is within specifications.
  8.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

The front wheel bearings are a cartridge type design and cannot be adjusted. To check for a loose wheel bearing, proceed as follows:

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheel.
  4.  
  5. Compress the caliper piston to free the caliper assembly.
  6.  
  7. Using a suitable dial indicator, measure the thrust play.
  8.  
  9. Push and pull the brake rotor by hand. If rotor movement exceeds 0.002 in. (0.05mm), replace the wheel bearings.
  10.  
  11. Install the wheel and lower the vehicle.
  12.  
  13. Apply the brakes several times before moving the vehicle, to seat the caliper piston.
  14.  

REMOVAL & INSTALLATION



Samurai Models

See Figures 2, 3, 4, 5 and 6

  1. Loosen all of the front/rear wheel lug nuts 1 / 2 turn.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the caliper mounting bolts and move the caliper out of position with the brake line attached.
  8.  

Do not allow the caliper to hang on the brake hose. Support it by the mounting bracket.

Click image to see an enlarged view

Fig. Fig. 2: Remove the front axle shaft drive flange circlip, securing bolts and flange

  1. Install two 8mm bolts into the threaded holes, and tighten them evenly. This will draw the rotor off of the hub assembly.
  2.  
  3. For models equipped with locking hubs, perform the following:
    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.  

  4.  
  5. For models not equipped with locking hubs, remove the front axle shaft cap and the circlip. Remove the drive flange from the steering knuckle.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Straighten the bent part of the lockwasher before removing the wheel bearing locknut

  1. Straighten the bent lockwasher, then remove the hub nut (wheel bearing locknut) and washer.
  2.  
  3. Remove the front wheel hub and bearing from the spindle.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Use the wheel bearing nut socket (B) to remove the outer locknut and loosen the inner nut



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Fig. Fig. 5: Remove the inner bearing nut

  1. Remove the oil seal and race from the wheel hub.
  2.  
  3. Clean and inspect the hub and bearing seats. Repack the wheel bearings. Install the new bearing, race and grease seal in the same position.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Pull the front wheel hub from the spindle

To install:
  1. Install the front wheel hub and bearing to the knuckle.
  2.  
  3. Tighten the bearing nut to 57 ft. lbs. (80 Nm) while spinning the hub by hand.
  4.  
  5. Loosen the nut to 0 ft. lbs., and then tighten it to the proper torque of 7-10 ft. lbs. (10-15 Nm). This will give the proper bearing preload.
  6.  
  7. Insert the lockwasher after adjustment, and tighten the locknut to 10-65 ft. lbs. (60-90 Nm). Bend a part of the lockwasher toward the bearing nut (on body side), and another toward the locknut (outside). this will lock the two nuts.
  8.  
  9. Install the drive flange to the steering knuckle.
  10.  
  11. For models equipped with free wheeling hubs, install the front axle cap and circlip. Connect the rotor to the hub assembly.
  12.  
  13. For models equipped with locking hubs, perform the following:
    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 18 ft. 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 9 ft. lbs. (13 Nm).
    12.  

  14.  

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.  

  1. Install the brake rotor.
  2.  
  3. Place the brake caliper into position and install the caliper mounting bolts.
  4.  
  5. If removed, reconnect the locking hub assembly and install the front wheels.
  6.  
  7. Lower the vehicle.
  8.  
  9. Pump the brake pedal several times to seat the front brake pads. Road test the vehicle and verify proper operation.
  10.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 7 through 16



Click image to see an enlarged view

Fig. Fig. 7: Cross-sectional view of the 2WD front hub and bearing components

  1. Loosen all of the front/rear wheel lug nuts 1 / 2 turn.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. If equipped with 4WD and automatic locking hubs, perform the following:
    1. Unscrew the automatic hub cover and remove the cover and O-ring.
    2.  
    3. Remove the hub assembly mounting bolts and remove the hub assembly.
    4.  

  8.  
  9. If equipped with 4WD and manual locking hubs, perform the following:
    1. Remove the six manual hub cover mounting bolts and remove he manual hub cover and gasket.
    2.  
    3. Remove the six manual hub mounting bolts.
    4.  
    5. Remove the manual hub and O-ring.
    6.  

  10.  
  11. If equipped with 2WD, remove the hub cap from the hub.
  12.  



Click image to see an enlarged view

Fig. Fig. 8: To remove the wheel hub and bearings, first remove the bearing lock plate which is secured by four screws

  1. Remove the caliper mounting bracket and position the caliper out of the way. Support the caliper.
  2.  
  3. Remove the brake rotor from the wheel hub. Remove the front wheel bearing lockplate screws, lockplate and washer.
  4.  
  5. Remove the wheel bearing locknut and washer, then remove the wheel hub complete with bearings and seals.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: Remove the wheel bearing locknut and washer using the special tool shown

If wheel hub cannot be removed by hand, use special tool J3781 with a J2619-01 for the Tracker or 0999-1511 with 09930-30102 for the Sidekick, Sidekick Sport and X-90 models, or their equivalents. These tools are a hub remover and sliding hammer.



Click image to see an enlarged view

Fig. Fig. 10: A slide hammer may be necessary to remove the assembly from the spindle

  1. If equipped with ABS brakes, remove the sensor rotor from the wheel hub.
  2.  

Pull out the sensor rotor from the wheel hub gradually and evenly. Pulling it out partially may cause it to deform.

Click image to see an enlarged view

Fig. Fig. 11: Cross-sectional view of the front wheel hub and bearing assembly

  1. Remove the inner bearing grease seal.
  2.  



Click image to see an enlarged view

Fig. Fig. 12: To remove the bearing from the hub, remove the snapring and rear oil seal ...



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Fig. Fig. 13: ... then press the bearing assembly out of the wheel hub

  1. Remove the snapring and remove the inner bearing.
  2.  
  3. Clean and inspect the hub and bearing seats.
  4.  

To install:
  1. Install the inner race, wheel bearing snapring and seal in the hub. Apply lithium grease to the lip portion of the oil seal.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Press the new bearing into the wheel hub until it contacts the stepped surface of the hub

  1. If equipped with ABS brakes, install the sensor rotor.
  2.  
  3. Install the hub on the spindle and install the outer bearing, locknut, washer, and lockplate. Tighten the locknut to 123-180 ft. lbs. (170-216 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 15: Drive in the two wheel hub oil seals. If the tool shown is not available, you may need to install the seals one at a time



Click image to see an enlarged view

Fig. Fig. 16: Apply lithium grease to the wheel hub seals as shown

  1. Install the four lockplate mounting screws. Tighten the screws to 8.8-17.7 inch lbs. (1-2 Nm).
  2.  
  3. Install the brake rotor.
  4.  
  5. Install the caliper and tighten the bolts to 61 ft. lbs. (85 Nm).
  6.  
  7. If equipped with 2WD, install the locking hub cap.
  8.  
  9. If equipped with 4WD and automatic locking hubs, perform the following:
    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 18 ft. lbs. (25 Nm).
    6.  
    7. Install a new O-ring on the hub cover.
    8.  
    9. Install the hub cover.
    10.  

  10.  
  11. If equipped with 4WD and manual locking hubs, complete the following sub-steps:
    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 18 ft. 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 71-106 inch lbs. (8-12 Nm).
    10.  

  12.  
  13. Install the wheels and lower the vehicle.
  14.  

 
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