Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Brake Shoes

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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.

INSPECTION



See Figure 1

  1. Remove the brake drum.
  2.  
  3. Use a vernier caliper to measure the thickness of the brake shoe lining and shoe backing. The minimum allowable lining/backing thickness (for all models) is 0.12 in. (3mm).
  4.  
  5. If one of the brake linings is worn to or beyond the allowable limit, all four of the rear brake shoes must be replaced.
  6.  



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Fig. Fig. 1: The combined thickness of the shoe lining material and shoe backing should be greater than 0.12 in. (3mm). Otherwise, install new brake shoes


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

  1. Install the brake drum.
  2.  

REMOVAL & INSTALLATION



Only service one side of the vehicle at a time, so that the other side can be used as a reference if you forget the proper arrangement of the brake items.

Samurai and 1989-95 Sidekick/Tracker Models

See Figure 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. Remove the brake drum.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the rear drum brake components-Samurai and 1989-95 Sidekick and Tracker models

  1. Remove the brake shoe hold-down springs by rotating the retaining pins 90 degrees.
  2.  
  3. On 1989-95 Sidekick and Tracker models, disengage the parking brake cable from the parking brake actuating lever.
  4.  
  5. Remove the shoes, return springs and strut from the backing plate.
  6.  
  7. Detach the upper and lower return springs, and the strut from the brake shoes.
  8.  
  9. On 1989-95 Sidekick and Tracker models, separate the parking brake lever from the trailing brake shoe by prying the C-clip off of the parking brake lever stud.
  10.  
  11. Thoroughly clean the backing plate, the brake springs and the strut.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: To remove the brake shoes, first remove the brake drum from the rear axle



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Fig. Fig. 4: Clean the brake parts with commercially available solvent. NEVER use compressed air to clean the parts



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Fig. Fig. 5: Grasp the shoe hold-down spring retaining pins, then turn them 90 degrees ...



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Fig. Fig. 6: ... and remove the hold-down springs and retaining pins from both brake shoes



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Fig. Fig. 7: Remove the shoes and springs from the backing plate and wheel cylinder ...



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Fig. Fig. 8: ... then detach the parking brake cable from the actuating lever

To install:
  1. Apply a thin coat of high temperature, multi-purpose grease to the backing plate where the shoes rub against it.
  2.  
  3. On 10989-95 Sidekick and Tracker models, apply a small amount of high temperature, multi-purpose grease to the parking brake lever where it rubs against the parking brake cable end.
  4.  



Click image to see an enlarged view

Fig. Fig. 9: Before installing the brake shoes, apply grease to the backing plate-to-brake shoe contact points

  1. On 1989-95 Sidekick and Tracker models, install the parking brake lever on the trailing shoe by inserting the lever stud through the brake shoe hole, then by installing and crimping a NEW C-clip onto the stud.
  2.  
  3. Assemble the return springs, strut and brake shoes, then position the new brake shoes on the backing plate.
  4.  
  5. On 1989-95 Sidekick and Tracker models, reattach the parking brake cable to the lever.