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 rear wheel lug nuts 1 / 2 turn. The rear wheels should be left on the axle assembly so that the assembly may be rolled out from beneath the vehicle.
  2.  
  3. Block the front wheels, then raise and safely support the rear of the vehicle with jackstands positioned beneath the frame rails.
  4.  
  5. Support the axle housing assembly with two hydraulic floor jacks.
  6.  
  7. Drain the axle housing assembly lubricant.
  8.  
  9. Detach and immediately plug the flexible rubber hose attaching the body brake line to the axle brake line from the axle brake line.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Before removing the axle housing, the flexible brake hose must be disconnected

  1. If equipped, remove the rear stabilizer bar.
  2.  
  3. Remove the rear driveshaft, as described earlier in this section.
  4.  
  5. Remove the rear shock absorbers, as described in Suspension & Steering .
  6.  
  7. Remove the rear leaf springs, as described in Suspension & Steering .
  8.  
  9. Carefully lower the axle assembly with the floor jacks, ensuring that no cables, wires or other components will inhibit axle assembly removal.
  10.  
  11. Roll the axle assembly out from beneath the vehicle.
  12.  
  13. The axle assembly may now be disassembled. The brake components and axle shaft procedures are covered elsewhere in this guide. The disassembly of the differential unit should be left to a professional automotive technician, unless you have extensive prior knowledge of this sort.
  14.  

To install:
  1. Assemble the axle assembly as necessary.
  2.  
  3. Roll the axle assembly into position beneath the vehicle, then slowly raise the axle on the two floor jacks.
  4.  
  5. Install the 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. If applicable, install the stabilizer bar.
  8.  
  9. Connect the flexible brake hose to the rear brake line.
  10.  
  11. Bleed the brake system, as described in Brakes .
  12.  
  13. Refill the differential with lubricant, as described in General Information & Maintenance .
  14.  
  15. Lower the vehicle, then tighten the rear wheel lug nuts to the specified value, as described in Suspension & Steering .
  16.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

  1. Loosen all of the rear wheel lug nuts 1 / 2 turn. The rear wheels should be left on the axle assembly so that the assembly may be rolled out from beneath the vehicle.
  2.  
  3. Block the front wheels, then raise and safely support the rear of the vehicle with jackstands positioned beneath the frame rails.
  4.  
  5. Support the axle housing assembly with two hydraulic floor jacks.
  6.  
  7. Drain the axle housing assembly lubricant.
  8.  
  9. Detach and label all wiring harness connectors from the rear axle assembly.
  10.  
  11. Detach and immediately plug the flexible rubber hose attaching the body brake line to the axle brake line from the axle brake line.
  12.  
  13. If equipped, remove the rear stabilizer bar.
  14.  
  15. Remove the rear driveshaft, as described earlier in this section.
  16.  
  17. Remove the rear shock absorbers, as described in Suspension & Steering .
  18.  
  19. Remove the rear coil springs, as described in Suspension & Steering .
  20.  
  21. Remove the trailing and upper arms, as described in Suspension & Steering .
  22.  
  23. Carefully lower the axle assembly with the floor jacks, ensuring that no cables, wires or other components will inhibit axle assembly removal.
  24.  
  25. Roll the axle assembly out from beneath the vehicle.
  26.  
  27. The axle assembly may now be disassembled. The brake components and axle shaft procedures are covered elsewhere in this guide. The disassembly of the differential unit should be left to a professional automotive technician, unless you have extensive prior knowledge of this sort.
  28.  

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

 
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