Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Tailgate and Back Door Locks

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REMOVAL & INSTALLATION



Samurai Models

See Figures 1 and 2

  1. Remove the inner door panel.
  2.  
  3. Peel the watershield off of the inside face of the door. If the watershield is not excessively damaged during removal (rips or tears may be repaired with waterproof tape), it may be reused. Otherwise, a new one can be purchased or fabricated from a plastic lawn bag.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the back door and lock mechanism, showing all related linkage, used on hard-top Samurai models

  1. Disconnect all actuating rods from the door lock mechanism.
  2.  
  3. Remove the door lock mounting fasteners, then remove it from the door. The inside handle is removed along with the door lock assembly.
  4.  

To install:
  1. Position the door lock/inside handle mechanism in the door, then install the mounting fasteners. Tighten the fasteners securely.
  2.  

When installing the door open rod to the lock mechanism, avoid depressing the push plate.

  1. Reattach all of the actuating rods to the door lock mechanism, keeping the following points in mind:

    When installing the door open rod on the outside handle, adjust the rod play clearance to 0.000-0.079 in. (0-2mm) by turning the adjusting joint. (Refer to the accompanying illustration.)
     

  2.  



Click image to see an enlarged view

Fig. Fig. 2: When reattaching the actuating rods to the lock mechanism, be sure to adjust the clearances to within the specified ranges



Be sure to engage the lock rod with the rod pin as indicated in the accompanying illustration.
 
If the inside door handle was detached from the door lock mechanism, adjust the clearance between the inside open lever and the outside open lever of the door lock to 0.000-0.079 in. (0-2mm) by moving the inside handle remote control rod in the direction of the arrow in the accompanying illustration.
 

After adjusting the various actuating rods, test the inside handle, the outside handle and the lock knob operation before installing the watershield on the door.

  1. Apply a continuous bead of sealant to the inner face of the door, then install the watershield on the door.
  2.  
  3. Install the door panel.
  4.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 3 and 4

Before proceeding with this procedure, purchase new inner tailgate panel retainers from a dealership or an aftermarket automotive parts store. The retainers are plastic, and the old ones will most likely break during panel removal.

  1. On Samurai models, remove the inner back door trim panel by loosening all of the retaining screws. Separate the panel from the back door.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the back door lock mechanism used on hard-top Sidekick, Tracker and Sidekick Sport models

  1. On Sidekick and Tracker models, remove the inner tailgate panel. Remove the inner tailgate panel plastic retainers by pressing the center pin of the retainer in until the retainer is fully disengaged, then pull the entire retainer out of the inner tailgate panel. Separate the panel from the tailgate.
  2.  
  3. Peel the watershield off of the inside face of the tailgate. If the watershield is not excessively damaged during removal (rips or tears may be repaired with waterproof tape), it may be reused. Otherwise, a new one can be purchased or fabricated from a plastic lawn bag.
  4.  
  5. Detach the outside tailgate handle rod from the tailgate lock assembly.
  6.  
  7. Disengage the lock cylinder lock rod from the tailgate lock assembly.
  8.  
  9. If equipped, detach the wiring harness connector from the tailgate lock assembly.
  10.  
  11. Loosen the lock assembly mounting screws, then remove the assembly from the tailgate.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: Use a Phillips head screwdriver to loosen the lock mounting screws, then remove the lock mechanism from the door

To install:
  1. Position the lock assembly in the tailgate, then install and tighten the tailgate lock assembly mounting screws securely.
  2.  
  3. Reattach the cylinder lock rod, and the outside tailgate handle rods to the tailgate lock assembly.
  4.  
  5. If necessary, reattach the wiring harness connector to the tailgate lock assembly.
  6.  
  7. Apply a continuous bead of sealant to the inner face of the tailgate, then install the watershield on the tailgate.
  8.  
  9. On Samurai models, position the inner tailgate panel against the inside of the tailgate, then install the retaining screws.
  10.  
  11. On Sidekick and Tracker models, position the inner tailgate panel against the inside of the tailgate, then insert new plastic retainers in the panel mounting holes. Engage the retainers by depressing the retainer center pins until they are flush the rest of the retainer.
  12.  

 
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