Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Wheel Cylinders

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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.

REMOVAL & INSTALLATION



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. See Figures 1 through 3

  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 rear wheels, brake drums and the rear brake shoes from the vehicle.
  6.  



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Fig. Fig. 1: To remove a wheel cylinder, remove the brake shoes, then detach the brake line(s) from the wheel cylinder



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Fig. Fig. 2: Loosen the wheel cylinder retaining bolts ...



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Fig. Fig. 3: ... then separate the wheel cylinder from the backing plate

  1. Detach and plug the brake line from the rear of the wheel cylinder.
  2.  
  3. Remove the 2 rear wheel cylinder mounting bolts, then separate the rear wheel cylinder from the backing plate.
  4.  

To install:
  1. Install the wheel cylinder onto the backing plate, then tighten the mounting bolts to 84 inch lbs. (9.5 Nm).
  2.  
  3. Reattach the brake line to the wheel cylinder, then tighten the flare nut to 124-150 inch lbs. (14-17 Nm).
  4.  
  5. Install the rear brake shoes, drums and wheels.
  6.  
  7. Lower the vehicle.
  8.  
  9. Bleed the brake system and check for any leaks when finished.
  10.  

OVERHAUL



See Figures 4 through 13

Wheel cylinder overhaul kits may be available, but often at little or no savings over a reconditioned wheel cylinder. It often makes sense with these components to substitute a new or reconditioned part instead of attempting an overhaul.

If no replacement is available, or you would prefer to overhaul your wheel cylinders, the following procedure may be used. When rebuilding and installing wheel cylinders, avoid getting any contaminants into the system. Always use clean, new, high quality brake fluid. If dirty or improper fluid has been used, it will be necessary to drain the entire system, flush the system with proper brake fluid, replace all rubber components, then refill and bleed the system.

  1. Remove the wheel cylinder from the vehicle and place on a clean workbench.
  2.  
  3. First remove and discard the old rubber boots, then withdraw the pistons. Piston cylinders are equipped with seals and a spring assembly, all located behind the pistons in the cylinder bore.
  4.  



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Fig. Fig. 4: Remove the outer boots from the wheel cylinder

  1. Remove the remaining inner components, seals and spring assembly. Compressed air may be useful in removing these components. If no compressed air is available, be VERY careful not to score the wheel cylinder bore when removing parts from it. Discard all components for which replacements were supplied in the rebuild kit.
  2.  



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Fig. Fig. 5: Compressed air can be used to remove the pistons and seals



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Fig. Fig. 6: Remove the pistons, cup seals and spring from the cylinder

  1. Wash the cylinder and metal parts in denatured alcohol or clean brake fluid.
  2.  



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Fig. Fig. 7: Use brake fluid and a soft brush to clean the pistons ...



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Fig. Fig. 8: ... and the bore of the wheel cylinder


WARNING
Never use a mineral-based solvent such as gasoline, kerosene or paint thinner for cleaning purposes. These solvents will swell rubber components and quickly deteriorate them.

  1. Allow the parts to air dry or use compressed air. Do not use rags for cleaning, since lint will remain in the cylinder bore.
  2.  
  3. Inspect the piston and replace it if it shows scratches.
  4.  



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Fig. Fig. 9: Once cleaned and inspected, the wheel cylinder is ready for assembly

  1. Lubricate the cylinder bore and seals using clean brake fluid.
  2.  
  3. Position the spring assembly.
  4.  
  5. Install the inner seals, then the pistons.
  6.  



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Fig. Fig. 10: Lubricate the cup seals with brake fluid



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Fig. Fig. 11: Install the spring, then the cup seals in the bore



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Fig. Fig. 12: Lightly lubricate the pistons, then install them

  1. Insert the new boots into the counterbores by hand. Do not lubricate the boots.
  2.  



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Fig. Fig. 13: The boots can now be installed over the wheel cylinder ends

  1. Install the wheel cylinder.
  2.  

 
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