Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Brake Pads

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REMOVAL & INSTALLATION



See Figure 1

Always replace all of the brake pads on the same axle at the same time; never replace the pads from one wheel only.


CAUTION
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.



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Fig. Fig. 1: Identification of front disc brake components mounted on the vehicle

  1. Siphon approximately 2 / 3 of the fluid out of the master cylinder.
  2.  
  3. Loosen all of the front wheel lug nuts 1 / 2 turn.
  4.  
  5. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  6.  
  7. Remove the wheels.
  8.  
  9. On Samurai models, use a small prytool to remove the caliper anti-rattle clip from the outboard side of the caliper.
  10.  



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Fig. Fig. 2: On Samurai models, use a small prytool to remove the anti-rattle clips from the outboard side of the caliper



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Fig. Fig. 3: Loosen the upper and lower guide pins ...



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Fig. Fig. 4: ... then lift the caliper up and off of the brake pads (A) and mounting bracket (B)



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Fig. Fig. 5: If the caliper is difficult to remove, use a large C-clamp to seat the caliper piston

  1. Remove the two guide pin caps (if equipped), then loosen the two guide pins with a wrench.
  2.  
  3. Lift the brake caliper off of the rotor, pads and pad mounting bracket, but do NOT disconnect the brake hose from the caliper.
  4.  


WARNING
Do not allow the caliper to hang from the brake hose; support it with strong wire or cord. Also, do not twist the brake hose or depress the brake pedal while the caliper is removed from the rotor.

  1. Remove the disc pads, and any shims, from the mounting bracket.
  2.  



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Fig. Fig. 6: Be sure to support the caliper aside with strong cord or wire; do not allow it to hang by the brake hose



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Fig. Fig. 7: Remove the outer brake pad ...



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Fig. Fig. 8: ... and separate the brake pad (A) from the shims (B), if any were used



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Fig. Fig. 9: Do the same for the inboard brake pads as well

To install:
  1. Using a large pair of channel locks or a C-clamp, press the caliper piston back into its bore. Be sure the piston is not cocked, and that it is pressed in straight.
  2.  
  3. Install the brake pads onto the mounting bracket.
  4.  

When installing the brake caliper, ensure that the rubber boots are fit securely in the grooves.

  1. Install the brake caliper over the brake rotor, pads and mounting bracket.
  2.  
  3. Install and tighten the guide pins to 19-2 ft. lbs. (25-30 Nm) for Samurai models, to 16-23 ft. lbs. (22-32 Nm) for Sidekick, Tracker and X-90 models, or the upper mounting bolt to 36 ft. lbs. (50 Nm) and the lower bolt to 42 ft. lbs. (58 Nm) for Sidekick Sport models.
  4.  
  5. If equipped, install the guide pin caps.
  6.  
  7. On Samurai models, install the anti-rattle clip on the outboard side of the caliper.
  8.  
  9. Install the front wheels.
  10.  
  11. Lower the vehicle, and fully tighten the wheel lug nuts.
  12.  


CAUTION
Do not attempt to drive the vehicle until after the following step is performed.

  1. Depress the brake pedal repeatedly until a firm pedal is obtained. Do not attempt to drive the vehicle unless a firm pedal is obtained.
  2.  
  3. Check the fluid level in the master cylinder. Add fresh brake fluid, as necessary.
  4.  
  5. Road test the vehicle.
  6.  

INSPECTION



See Figure 2


WARNING
Never polish the pad lining with sandpaper, because hard particles from the sandpaper will become imbedded in the lining, which will damage the brake rotor. If the pad lining is damaged or worn excessively or unevenly, replace the pads with new ones.

To inspect the brake pad lining, remove the brake caliper without disconnecting the flexible brake hose from it. Then, inspect the brake pad lining for damage, such as crumbling, missing chunks, uneven wear, etc. Also, measure the combined thickness of the pad lining and the pad backing. The minimum allowable brake pad lining thickness should be as follows:



Samurai models-0.236 in. (6mm)
 
1989-95 Sidekick and Tracker models-0.315 in. (8mm)
 
1996-98 2-door Sidekick, Tracker and X-90 models-0.236 in. (6mm)
 
1996-98 4-door Sidekick and Tracker models-0.295 in. (7.5mm)
 
1996-98 Sidekick Sport models-0.275 in. (7mm)
 



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Fig. Fig. 10: Use a vernier caliper to measure the brake pad lining and baking thickness. Install new pads if they are worn too thin

If there are signs of damage, or if the lining and backing thickness is less than specified, replace the pads with new ones.

 
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