Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Lower Control Arms

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REMOVAL & INSTALLATION



Sidekick, Tracker, Sidekick Sport and X-90 Models
  1. Loosen all of the front 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 wheel.
  6.  
  7. Remove the engine skid plate, if equipped.
  8.  
  9. Support the lower control arm with a floor jack.
  10.  
  11. Remove the 3 nuts and bolts from the control arm, separating the control arm from the ball joint.
  12.  
  13. Disconnect the stabilizer bar from the control arm.
  14.  


CAUTION
The coil spring is under pressure. Make sure control arm is firmly supported with a hydraulic jack before continuing with procedure. If this precaution is not observed, serious bodily injury may result.

  1. Remove the lower strut mounting bracket bolts and disconnect the strut bracket from the steering knuckle.
  2.  
  3. Lower the jack until all tension is removed from the coil spring. Remove the coil spring from the vehicle.
  4.  
  5. Remove the front and rear through-bolts from the control arm and remove the control arm from the vehicle.
  6.  

To install:
  1. Install the new control arm, then tighten the front bolt and nut to 51-75 ft. lbs. (70-100 Nm), and the rear bolt and nut to 65-101 ft. lbs. (90-140 Nm).
  2.  
  3. Install the coil spring onto the control arm and slowly raise the jack.
  4.  

The bottom of the spring has a larger diameter than the top. Make sure that the spring is installed correctly.

  1. Install the strut-to-knuckle mounting nuts and bolts and tighten to 58-75 ft. lbs. (80-100 Nm).
  2.  
  3. Connect the stabilizer link to the control arm, then tighten the nut to 16-25 ft. lbs. (3-35 Nm).
  4.  
  5. Install the 3 nuts and bolts connecting the control arm and ball joint, and tighten the nuts to 51-75 ft. lbs. (70-100 Nm).
  6.  
  7. Install the engine skid plate. Tighten the bolts to 40 ft. lbs. (54 Nm).
  8.  
  9. Install the front wheels, then lower the vehicle.
  10.  
  11. Tighten the wheel lug nuts.
  12.  

CONTROL ARM BUSHING REPLACEMENT



See Figures 1, 2, 3, 4 and 5

  1. Remove the lower control arm from the vehicle.
  2.  
  3. Position the lower control arm in a padded vise.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: To remove the front control arm bushing, cut off the front flange as shown ...

  1. Using a hacksaw, cut off approximately 0.1 in. (5mm) from the front bushing flange, as shown in the accompanying illustration.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: ... then press the bushing from the control arm using the special tools (A, B and C) as shown

  1. Position the control arm in a hydraulic press so that the bushing can be pressed out of the control arm using Suzuki press adapters 09951-16060, 0995-74510, and 09951-4601 or their equivalents.
  2.  
  3. Use a knife to cut off the bushing flange surface of the rear bushing.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: To remove the rear control arm bushing, cut off the flange with a knife, then press the bushing out in a similar manner as the front

  1. Use the hydraulic press to drive the rear bushing out of the lower control arm with Suzuki tools 09951-16040 or their equivalent.
  2.  

To install:

When installing the front bushing, position it so that the hollow areas are placed as shown in the accompanying illustration. Also, applying a thin coat of grease to the inside of the control arm will make installation much easier.



Click image to see an enlarged view

Fig. Fig. 4: When installing the front bushing, position it in the control arm as shown

  1. To install the front bushing, use the hydraulic press to drive the new bushing into the lower control arm until the bushing flange contacts the edge of the lower arm housing. Use the appropriate hydraulic press adapters and spacers, as shown in the accompanying illustration.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Press the bushings in until the flange contacts the housing edge

Applying a thin coat of soapy water on the outside surface of the bushing will help facilitate installation.

  1. To install the rear bushing, use the hydraulic press to drive the new bushing into the lower control arm until the bushing flange contacts the edge of the lower arm housing. Use the appropriate hydraulic press adapters (D) and spacers (Suzuki tool 09951-16040 or equivalent), as shown in the accompanying illustration.
  2.  
  3. Install the lower control arm on the vehicle.
  4.  

 
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