Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Cable(s)

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ADJUSTMENT



See Figure 1

  1. Ensure the following conditions are met before adjusting the parking brake cable:

    No air is trapped in the brake system.
     
    Brake pedal travel in within specifications.
     
    The brake pedal has been depressed a few times with about 44 lbs. (20 kg) of force applied and released.
     
    The parking brake lever has been applied up a few times with about 44 lbs. (20 kg) of force applied and released.
     
    Rear brakes are not worn beyond the limits and the self adjusting mechanism operates properly.
     

  2.  



Click image to see an enlarged view

Fig. Fig. 1: Parking brake routing, retaining clip location and component identification-Samurai shown, others similar

For Samurai models, loosen the stopper nut, then adjust the parking brake lever by loosening or tightening the self locking nut at the parking brake lever. While turning the adjusting nut, secure the holding nut with a wrench to prevent the inner cable from twisting. After the adjustment is complete, tighten the stopper nut against the pin.

For Sidekick, Tracker, Sidekick Sport and X-90 models, adjust the parking brake cable by loosening or tightening the self locking nut at the rear of the parking brake lever.

For all models, proper adjustment is when the parking brake lever engages 3-8 notches from the released position, when the lever is pulled up with a force of 44 lbs. (20 kg).

When the lever is applied to the aforementioned number of notches, the rear wheels should not move. The rear wheels should turn freely after the parking brake is released. Check the rear drum for dragging after adjustment.

REMOVAL & INSTALLATION



Samurai Models
  1. Disconnect the parking brake cable from the parking lever.
  2.  
  3. Loosen all of the rear wheel lug nuts 1 / 2 turn.
  4.  
  5. Block the front wheels, then raise and safely support the rear of the vehicle.
  6.  
  7. Remove the rear wheels and brake drums from the vehicle.
  8.  
  9. Remove the rear brake shoes and disconnect the parking brake cable from the parking brake shoe lever.
  10.  
  11. Remove the cable from the brake backing plate by squeezing the parking brake cable stop ring. Often an appropriately-sized box end wrench compresses the stop ring easily for removal.
  12.  
  13. Remove the parking brake cable from its chassis holding clamps.
  14.  

To install:
  1. Install the cable to the backing plate and to the brake shoe lever. Make sure to route the cable through its chassis holding clamps.
  2.  
  3. Install the brake shoes and install the rear brake drums.
  4.  
  5. Install the rear wheels and connect the cable to the parking brake lever.
  6.  
  7. Lower the vehicle.
  8.  
  9. Ensure the parking brake is functioning properly, and adjust the cable if necessary.
  10.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

  1. Block the vehicle wheels and release the parking brake lever.
  2.  
  3. Remove the two screws and one clip securing the parking brake lever cover in place and remove the cover.
  4.  
  5. Remove the parking brake cable locknut and washer.
  6.  
  7. Disconnect the connecting rod from the equalizer.
  8.  
  9. Loosen all of the rear wheel lug nuts 1 / 2 turn.
  10.  
  11. Block the rear wheels, then raise and safely support the rear of the vehicle on jackstands.
  12.  
  13. Remove the rear wheels and brake drums from the vehicle.
  14.  



Click image to see an enlarged view

Fig. Fig. 2: When removing the cable from the backing plate, a box end wrench works well to depress the cable retaining clip fingers

  1. Remove the rear brake shoes.
  2.  
  3. Disconnect the parking brake cable from the parking brake shoe lever.
  4.  
  5. Remove the cable from the brake backing plate by squeezing the parking brake cable stop ring. Often an appropriately-sized box end wrench compresses the stop ring easily for removal.
  6.  
  7. Remove the four bolts securing the cable housing to the underbelly of the vehicle.
  8.  
  9. Remove the cable from the vehicle.
  10.  

To install:
  1. Position the cable in the vehicle and install the four underbelly mounting bolts. Feed the cable up through the hole in the floor and seat the grommet in place.
  2.  
  3. Connect the cable housing to the backing plate and install the cable stopper ring. Connect the cable end to the brake shoe lever.
  4.  
  5. Install the brake shoes and install the rear brake drums.
  6.  
  7. Install the rear wheels.
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the parking brake cable to the equalizer.
  12.  
  13. Connect the equalizer to the connecting rod and install the washer and nut. DO NOT tighten the nut at this time.
  14.  
  15. Adjust the parking brake, and tighten the nut.
  16.  
  17. Install the brake lever cover and install the clip and two mounting bolts.
  18.  
  19. Apply the parking brake and remove the wheel blocks.
  20.  

 
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