Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Proportioning and Differential Valve

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REMOVAL & INSTALLATION




CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

The Samurai model does not use this type of proportioning valve; it only uses a LSPV.

Sidekick, Tracker, and X-90 Models
WITHOUT ABS

WARNING
Do not allow brake fluid to come into contact with painted surfaces; the brake fluid can easily damage painted finishes.

The proportioning valve is mounted on the inboard side of the front, right-hand frame rail, near the firewall.

  1. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  2.  
  3. If equipped, detach the wiring harness connector from the proportioning valve.
  4.  
  5. Disconnect and plug the hydraulic brake lines from the proportioning valve assembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Fig. 1: The proportioning valve (arrow) is mounted on the right-hand, front frame rail

  1. Remove the proportioning valve from the frame rail.
  2.  


WARNING
Never disassemble the proportioning valve, which would damage the component beyond repair. If it is found to be defective, replace it with a new one.

To install:
  1. Install the proportioning valve onto the frame rail, then tighten the mounting bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Attach all of the hydraulic brake lines to the proportioning valve, then tighten the fittings to 124-159 inch lbs. (1-18 Nm).
  4.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always purchase the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. NEVER reuse any brake fluid. Brake fluid that is removed from the hydraulic system should be discarded.

Be sure to also bleed the air from the proportioning valve bleeder screw (if equipped) during the bleeding procedure.

  1. Fill the brake reservoir to the proper level and bleed the brake hydraulic system.
  2.  
  3. Lower the vehicle and remove the wheel blocks.
  4.  

WITH REAR WHEEL ANTI-LOCK (RWAL) SYSTEM

See Figure 1


WARNING
Do not allow brake fluid to come into contact with painted surfaces; the brake fluid can easily damage painted finishes.

  1. Open the hood, then remove the air cleaner case assembly.
  2.  
  3. Detach the wiring harness connector from the proportioning valve.
  4.  
  5. Disconnect and plug the hydraulic brake lines from the proportioning valve assembly.
  6.  
  7. Remove the proportioning valve from the master cylinder.
  8.  


WARNING
Never disassemble the proportioning valve, which would damage the component beyond repair. If it is found to be defective, replace it with a new one.

To install:
  1. Install the proportioning valve to the master cylinder, then tighten the mounting bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Attach all of the hydraulic brake lines to the proportioning valve, then tighten the fittings to 124-159 inch lbs. (1-18 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 2: During installation, be sure to properly tighten the mounting bolts and brake line fittings to the specified values


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always purchase the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. NEVER reuse any brake fluid. Brake fluid that is removed from the hydraulic system should be discarded.

Be sure to also bleed the air from the proportioning valve bleeder valve during the bleeding procedure.

  1. Fill the brake reservoir to the proper level and bleed the brake hydraulic system.
  2.  

WITH 4-WHEEL ABS

1996-98 Sidekick, Tracker and X-90 models equipped with the Anti-Lock Brake System (ABS) require a scan tool to properly bleed the brake system. If you are servicing such a vehicle, please refer to the applicable ABS information located at the end of this information BEFORE you perform any brake procedures.

The proportioning valve is an integral part of the ABS actuator assembly, and cannot be separately removed.

Sidekick Sport Models
  1. Open the hood, then remove the air cleaner case assembly.
  2.  
  3. Detach the wiring harness connector from the proportioning valve.
  4.  
  5. Disconnect and plug the hydraulic brake lines from the proportioning valve assembly.
  6.  
  7. Remove the proportioning valve from the master cylinder.
  8.  


WARNING
Never disassemble the proportioning valve, which would damage the component beyond repair. If it is found to be defective, replace it with a new one.

To install:
  1. Install the proportioning valve to the master cylinder, then tighten the mounting bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Attach all of the hydraulic brake lines to the proportioning valve, then tighten the fittings to 124-159 inch lbs. (1-18 Nm).
  4.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always purchase the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. NEVER reuse any brake fluid. Brake fluid that is removed from the hydraulic system should be discarded.

Be sure to also bleed the air from the proportioning valve bleeder valve during the bleeding procedure.

  1. Fill the brake reservoir to the proper level and bleed the brake hydraulic system.
  2.  

 
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