Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Brake Drums

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REMOVAL & INSTALLATION



Samurai Models

See Figures 1, 2, 3 and 4


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.

  1. Loosen all of the rear wheel lug nuts 1 / 2 turn.
  2.  
  3. Block the rear wheels, then raise and safely support the rear of the vehicle on jackstands.
  4.  
  5. If engaged, release the parking brake.
  6.  



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Fig. Fig. 1: To remove the brake drum, detach the parking brake cable from the parking brake shoe lever by removing the pin and clip ...



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Fig. Fig. 2: ... then remove the parking brake shoe lever stopper plate



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Fig. Fig. 3: If the drum is difficult to remove from the rear axle shaft, use a slide hammer and adapter to pull the drum off

  1. Remove the rear wheels.
  2.  
  3. If equipped, remove the rear drum nuts from the vehicle.
  4.  
  5. To increase the clearance between the brake shoe and drum, remove the parking brake shoe lever return spring, and detach the parking brake cable joint from the shoe lever.
  6.  
  7. Remove the parking brake shoe lever stopper plate.
  8.  
  9. Pull the brake drum off of the rear axle shaft flange. If the brake drum is difficult to separate from the axle flange, use a slide hammer.
  10.  

To install:
  1. Install the parking brake shoe lever stopper plate.
  2.  


WARNING
Inspect the joint pin clip for deformation or breakage; replace it with a new one if any damage is evident.

  1. Connect the brake cable joint to the parking brake shoe lever by using the joint pin. Insert the pin down from the top, then install the clip into the joint pin hole.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Use a small prytool to depress the ratchet mechanism, which will maximize the brake shoe-to-drum clearance for assembly

  1. Install the parking brake lever return spring.
  2.  
  3. Insert a small prytool between the rod and ratchet of the brake shoe adjuster mechanism, then push the ratchet down.
  4.  
  5. Install the brake drum, and tighten the brake drum nuts to 58 ft. lbs. (79 Nm).
  6.  
  7. Install the rear wheels, and lower the vehicle.
  8.  
  9. Before driving the vehicle, depress the brake pedal 4 or 5 times to seat the rear drum brake shoes.
  10.  
  11. Raise and safely support the rear of the vehicle on jackstands. Spin the rear wheels to ensure that the brakes are not adjusted too tightly. Lower the vehicle and remove the front wheel blocks.
  12.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 5 and 6


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.

  1. Loosen all of the rear wheel lug nuts 1 / 2 turn.
  2.  
  3. Block the front wheels, then raise and safely support the rear of the vehicle on jackstands.
  4.  
  5. Remove the wheel and tire assembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Loosen the four brake drum retaining bolts. A large prytool can hold the drum steady during nut loosening



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Fig. Fig. 6: Lift the parking brake lever cover so that the parking brake cable adjusting nut can be loosened

  1. On 1989-95 models, remove the four brake drum nuts from the brake drum.
  2.  
  3. From inside the passenger's compartment, relieve the parking brake cable tension by removing the parking brake lever cover screws and pulling up on the brake lever cover. Loosen the parking brake cable locknut.
  4.  
  5. On 1989-95 models, from under the rear of the vehicle, remove the plug from the backing plate to gain access to the hold-down spring. Once the plug is removed, insert a brake spoon tool or flat prytool into the plug hole until its tip contacts the brake shoe hold-down spring. Push the spring in to release the parking brake shoe lever from the hold-down spring, which will backs the brake shoes off from the brake drum.
  6.  
  7. On 1989-95 models, pull the brake drum off of the rear axle flange. If the brake drum is difficult to remove, use a slide hammer and a special tool (such as Suzuki tool 09943-35511) to pull the brake drum off.
  8.  
  9. On 1996-98 models, install two 8mm bolts into the brake drum holes and uniformly tighten each bolt. Tighten each bolt until the brake drum is removed from the vehicle. If there is difficulty in removing the drum, insert a small tool through the hole in the rear of the backing plate, and hold the automatic adjusting lever away from the adjuster. Using another narrow, flat tool at the same time, reduce the brake shoe adjuster by turning the adjusting wheel.
  10.  
  11. Inspect the brake drum for wear and/or scoring. Machine or replace, as necessary.
  12.  



Click image to see an enlarged view

Fig. Fig. 7: Remove the access plug from the backing plate ...



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Fig. Fig. 8: ... then use a brake "spoon" to depress the brake shoe hold-down spring (located inside the drum)



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Fig. Fig. 9: Depressing the shoe hold-down spring should allow the parking brake lever to disengage inside the drum, which will provide more brake shoe-to-drum clearance for drum removal



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Fig. Fig. 10: Pull the brake drum off of the rear axle flange

To install:
  1. On 1989-95 models, before installing the brake drum, maximize the brake shoe-to-drum clearance by inserting a small prytool between the rod and ratchet of the brake shoe adjuster mechanism, then pushing the ratchet down.
  2.  
  3. On 1996-98 models, perform the following to automatically adjust the brake shoes:
    1. Install the brake drum and pull the parking brake lever all the way up until a clicking sound can no longer be heard.
    2.  
    3. Verify that the rear wheels will not turn. If the rear wheels turn, adjust the parking brake cable as necessary.
    4.  
    5. Release the parking brake and remove the brake drum. Using a caliper gauge, measure the outside diameter of the brake shoes. Outside diameter should be as follows:

      For 2-door models-8.637-8.639 in. (21.87-21.93cm)
       
      For 4-door models-9.972-9.988 in. (3.33-3.37cm)
       

    6.  
    7. If the brake shoe clearance is not correct, adjust the brake shoes (by turning the star wheel) until the clearance is correct.
    8.  

  4.  
  5. On 1989-95 models, move the brake shoe hold-down spring back into its original position.
  6.  
  7. Slide the brake drum onto the axle flange.
  8.  
  9. On 1989-95 models, install the four drum retaining nuts. Tighten the drum retaining nuts to 37-57 ft. lbs. (50-80 Nm).
  10.  
  11. If necessary, install the plug in the brake backing plate.
  12.  
  13. Install the wheel and tire assembly, then lower the vehicle.
  14.  
  15. Fully tighten the lug nuts.
  16.  
  17. Before driving the vehicle, depress the brake pedal hard 4 or 5 times to seat the rear drum brake shoes.
  18.  
  19. Raise and safely support the rear of the vehicle on jackstands. Spin the rear wheels to ensure that the brakes are not adjusted too tightly. Lower the vehicle and remove the front wheel blocks.
  20.  

INSPECTION



See Figure 7

While the brake drum is removed from the vehicle, inspect the wheel cylinder for damage and leakage.

  1. Remove the brake drum from the vehicle.
  2.  


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.

  1. Thoroughly clean the brake drum.
  2.  
  3. Inspect the brake drum for cracks, scores deep grooves, etc. A damaged drum is unsafe for use, and should be replaced immediately. Do not attempt to weld a cracked drum. If the drum exhibits scoring, and there is enough metal left on the inside diameter of the drum, have the drum cut by a qualified automotive machine shop. Slight scoring can be smoothed using emery cloth.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: Measure the brake drum inside diameter with a caliper gauge. If the diameter is too large, the drum must be replaced with a new one

  1. Inspect the drum for excessive wear by measuring the inside diameter of the brake drum with a caliper gauge. The maximum inside drum diameter allowable is as follows:

    Samurai models-8.74 in. (22.2cm)
     
    1989-91 Sidekick and Tracker models-8.74 in. (22.2cm)
     
    1992-93 2-door Sidekick and Tracker models-8.74 in. (22.2cm)
     
    1992-93 4-door Sidekick and Tracker models-10.07 in. (3.6cm)
     
    1994-95 Sidekick and Tracker models-10.07 in. (3.6cm)
     
    1996-98 2-door Sidekick, Tracker, Sidekick Sport and X-90 models-8.74 in. (22.2cm)
     
    1996-98 4-door Sidekick, Sidekick Sport and Tracker models-10.07 in. (3.6cm)
     

  2.  
  3. If the brake drum exhibits damage, or if the inside diameter is larger than specified, replace it with a new one.
  4.  

 
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