Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION




CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

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 section located at the end of this section BEFORE you perform any brake procedures.



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Fig. Fig. 1: To remove the caliper, loosen the brake hose-to-caliper union bolt ...



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Fig. Fig. 2: ... then remove the union bolt (A) and washer (B), thereby detaching the brake hose (C) from the caliper (D)



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Fig. Fig. 3: Be sure to remove BOTH copper washers from the brake hose and caliper. New ones will be needed during assembly



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Fig. Fig. 4: Loosen the caliper guide pins, then lift the caliper up and off of the rotor and brake pads


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

  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 wheels.
  6.  
  7. Clean the brake caliper with commercially available brake cleaning spray.
  8.  
  9. Disconnect and plug the flexible brake line.
  10.  
  11. Remove the caliper mounting bolts (guide pins), then remove the caliper from the brake pad mounting bracket.
  12.  

To install:
  1. Install the caliper over the brake pads and mounting bracket.
  2.  
  3. Install and tighten the mounting bolts (guide pins) to 19-21 ft. lbs. (25-30 Nm) for Samurai, Sidekick, Tracker and X-90 models, or the bottom bolt to 37 ft. lbs. (50 Nm) and the top bolt to 42 ft. lbs. (58 Nm) for Sidekick Sport models.
  4.  
  5. Connect the hydraulic brake line, using two new washers, to the caliper. Tighten the flexible hose union bolt to 177-221 inch lbs. (20-25 Nm).
  6.  
  7. Install the front wheels.
  8.  
  9. Lower the vehicle, then fully tighten the front wheel lug nuts.
  10.  


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.

  1. Fill the brake reservoir and bleed the hydraulic brake system.
  2.  

OVERHAUL



See Figures 5 through 12

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

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      Fig. Fig. 5: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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      Fig. Fig. 6: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



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Fig. Fig. 7: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 8: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 9: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 10: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Fig. 11: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 12: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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