Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Steering Linkage

Print

REMOVAL & INSTALLATION



See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Typical leaf spring equipped steering linkage components



Click image to see an enlarged view

Fig. Fig. 2: Typical coil spring equipped steering linkage components

Idler Arm

See Figures 3 and 4

This procedure applies to Sidekick, Tracker, Sidekick Sport and X-90 models only.

  1. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. Withdraw the center link-to-idler arm ball joint cotter pin, then loosen the center link ball joint castle nut.
  4.  
  5. Using a tie rod end separator, detach the center link ball joint from the idler arm.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the idler arm-to-center link cotter pin and castellated nut, then disconnect them with a tie rod separator tool



Click image to see an enlarged view

Fig. Fig. 4: Remove the idler arm bushing nut and pull the idler arm from the vehicle

  1. Loosen the idler arm bushing nut, then remove the idler arm and bushing from the vehicle.
  2.  
  3. If necessary, drive the bushing out of the idler arm with a hydraulic press.
  4.  

To install:
  1. If the idler arm bushing was removed, drive a new bushing into the idler arm with a hydraulic press.
  2.  
  3. Install the upper washer, idler arm, lower washer, lockwasher and nut on the idler arm shaft. Tighten the nut to 51-57 ft. lbs. (70-80 Nm).
  4.  
  5. Position the idler arm over the center link ball joint stud and install the castle nut. Tighten the castle nut to 22-50 ft. lbs. (30-70 Nm). Insert a new cotter pin through the castle nut and center link stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the center link stud hole, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
  6.  
  7. Lower the vehicle and remove the rear wheel blocks.
  8.  

Tie Rod Ends

See Figures 5, 6, 7 and 8



Click image to see an enlarged view

Fig. Fig. 5: To remove a tie rod end, first remove the cotter pin from the castellated nut ...



Click image to see an enlarged view

Fig. Fig. 6: ... then loosen and remove the nut



Click image to see an enlarged view

Fig. Fig. 7: Use a tie rod separator tool to disconnect the tie rod end from the steering knuckle



Click image to see an enlarged view

Fig. Fig. 8: Loosen the adjusting (turnbuckle) locknut, then remove the tie rod end

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 rear of the vehicle on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the cotter pin and castle nut from the outer tie rod end.
  8.  
  9. Separate the outer tie rod end from the steering knuckle, using a tie rod end remover tool.
  10.  
  11. Mark the outer tie rod end jam nut position on the inner tie rod threads.
  12.  
  13. Loosen the jam nut, then remove the outer tie rod end from the inner tie rod.
  14.  

To install:
  1. Install the tie rod end onto the inner tie rod. Align the jam nut with the mark on the tie rod thread, and tighten the jam nut to 37-58 ft. lbs. (50-80 Nm).
  2.  
  3. Connect the tie rod end to the steering knuckle. Tighten the castle nut until the holes of the split pin are aligned but only within the specified torque of 22-39 ft. lbs. (30-55 Nm). Install a new cotter pin.
  4.  
  5. Install the tires.
  6.  
  7. Lower the vehicle, and remove the rear wheel blocks.
  8.  
  9. Check and adjust the front end alignment as necessary.
  10.  

SAMURAI MODELS-LEFT-HAND TIE ROD END
  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 rear of the vehicle on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the cotter pin and castle nut from the outer tie rod end.
  8.  
  9. Separate the outer tie rod end from the steering knuckle, using a tie rod end remover tool.
  10.  
  11. Mark the outer tie rod end jam nut position on the inner tie rod threads.
  12.  
  13. Loosen the jam nut, then remove the outer tie rod end from the inner tie rod.
  14.  

To install:
  1. Install the tie rod end onto the inner tie rod. Align the jam nut with the mark on the tie rod thread, and tighten the jam nut to 51-72 ft. lbs. (70-100 Nm).
  2.  
  3. Connect the tie rod end to the steering knuckle. Tighten the castle nut until the holes of the split pin are aligned but only within the specified torque of 22-39 ft. lbs. (30-55 Nm). Install a new cotter pin.
  4.  
  5. Install the tires.
  6.  
  7. Lower the vehicle, and remove the rear wheel blocks.
  8.  
  9. Check and adjust the front end alignment as necessary.
  10.  

SAMURAI MODELS-RIGHT-HAND TIE ROD END
  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 rear of the vehicle on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the cotter pin and castle nut from the left-hand outer tie rod end.
  8.  
  9. Separate the left-hand outer tie rod end from the steering knuckle, using a tie rod end remover tool.
  10.  
  11. Mark the outer tie rod end jam nut position on the inner tie rod threads.
  12.  
  13. Loosen the jam nut, then remove the outer tie rod end from the inner tie rod.
  14.  
  15. Withdraw the drag rod-to-right tie rod end ball joint cotter pin, then loosen the castle nut.
  16.  
  17. Using a tie rod end separator, detach the drag rod from the right-hand tie rod.
  18.  
  19. Remove the cotter pin and castle nut from the right-hand tie rod end.
  20.  
  21. Separate the right-hand tie rod end from the steering knuckle, using a tie rod end remover tool.
  22.  

To install:
  1. Connect the right-hand tie rod to the steering knuckle. Tighten the castle nut until the holes of the split pin are aligned but only within the specified torque of 22-39 ft. lbs. (30-55 Nm). Install a new cotter pin.
  2.  
  3. Insert the right-hand tie rod ball stud through the drag rod hole. Install the castle nut hand-tight. Then, tighten the castle nut to 22-39 ft. lbs. (30-55 Nm). Insert a new cotter pin through each of the castle nuts and stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the stud, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
  4.  
  5. Install the tie rod end onto the inner tie rod. Align the jam nut with the mark on the tie rod thread, and tighten the jam nut to 51-72 ft. lbs. (70-100 Nm).
  6.  
  7. Connect the tie rod end to the steering knuckle. Tighten the castle nut until the holes of the split pin are aligned but only within the specified torque of 22-39 ft. lbs. (30-55 Nm). Install a new cotter pin.
  8.  
  9. Install the tires.
  10.  
  11. Lower the vehicle, and remove the rear wheel blocks.
  12.  
  13. Check and adjust the front end alignment as necessary.
  14.  

Center Link

This procedure applies to Sidekick, Tracker, Sidekick Sport and X-90 models only.

  1. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. Withdraw the center link-to-idler arm and center link-to-Pitman arm ball joint cotter pins, then loosen the center link ball joint castle nuts.
  4.  
  5. Using a tie rod end separator, detach the center link ball joints from the idler and Pitman arms.
  6.  
  7. Withdraw the center link-to-outer tie rod end ball joint cotter pins, then loosen the outer tie rod end ball joint castle nuts.
  8.  
  9. Using a tie rod end separator, detach the center link from the outer tie rod ends.
  10.  

To install:
  1. Insert the outer tie rod end ball studs through the center link holes. Install the castle nuts hand-tight.
  2.  
  3. Engage the idler arm and Pitman arm with the center link ball joint studs, then install the castle nuts hand-tight.
  4.  
  5. Tighten all of the castle nuts to 22-50 ft. lbs. (30-70 Nm). Insert a new cotter pin through each of the castle nuts and stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the stud, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
  6.  
  7. Lower the vehicle and remove the rear wheel blocks.
  8.  

Drag Rod

This procedure applies to Samurai models only.

  1. If necessary, apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. Withdraw the drag rod-to-Pitman arm ball joint cotter pin, then loosen the castle nut.
  4.  
  5. Using a tie rod end separator, detach the drag rod from the Pitman arm.
  6.  
  7. Withdraw the drag rod-to-right tie rod end ball joint cotter pin, then loosen the castle nut.
  8.  
  9. Using a tie rod end separator, detach the drag rod from the right-hand tie rod.
  10.  

To install:
  1. Insert the right-hand tie rod ball stud through the drag rod hole. Install the castle nut hand-tight.
  2.  
  3. Engage the Pitman arm with the drag rod, then install the castle nut hand-tight.
  4.  
  5. Tighten all of the castle nuts to 22-39 ft. lbs. (30-55 Nm). Insert a new cotter pin through each of the castle nuts and stud holes, then bend the cotter pin ends over. If none of the castle nut grooves are aligned with the hole in the stud, continue tightening the castle nut until one of the grooves is aligned with the stud hole, then install the cotter pin.
  6.  
  7. If necessary, lower the vehicle and remove the rear wheel blocks.
  8.  

 
label.common.footer.alt.autozoneLogo