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.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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 ...



Click image to see an enlarged view

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.
  6.  
  7. Install the shoe hold-down springs by pushing them down in place, and turning the retaining pins.
  8.  
  9. Install the rear brake drum, as described earlier in this information.
  10.  

1996-98 Sidekick, Tracker, Sidekick Sport and X-90 Models

The 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.

  1. Remove the brake drum.
  2.  
  3. Remove the pawl lever and adjusting spring.
  4.  
  5. Remove the upper shoe return spring and adjuster.
  6.  
  7. Remove the shoe hold-down springs by depressing the spring and rotating it 90 degrees.
  8.  
  9. Remove the brake shoes and lower spring from the backing plate.
  10.  
  11. Detach the lower return spring from both brake shoes, then detach the parking brake cable from the actuating lever, mounted on the trailing shoe.
  12.  
  13. Separate the parking brake lever from the trailing brake shoe by prying the C-clip off of the parking brake lever stud.
  14.  
  15. Thoroughly clean the backing plate, the brake springs and the strut.
  16.  

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. 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.  
  5. Install the parking brake actuating 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.
  6.  
  7. Assemble the two brake shoes and the lower return spring, then position them on the backing plate.
  8.  
  9. Install the shoe hold-down springs by positioning them over the retaining pins, depressing them and turning them 90 degrees.
  10.  


CAUTION
Be very careful when installing the upper return spring; if it is not installed properly, it may come dislodged from one of the shoes and cause injury.

  1. Install the upper shoe return spring and adjuster.
  2.  
  3. Install the pawl lever and adjusting spring.
  4.  
  5. Install the rear brake drum, as described earlier in this information.
  6.  

ADJUSTMENTS



All of the drum brakes used on these vehicles adjust automatically. No manual adjustment is necessary.

 
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