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Disc & Drum: Removal & Installation Suzuki Vitara I

Mechanical - Hydraulic 10 illustrations ~1755 words

Removal & Installation

Raise and support vehicle. Remove front wheels. Remove caliper pin bolts. Remove "E" ring from strut assembly. Remove caliper from caliper carrier and wire aside. Remove brake pads and anti-noise clips. (Scheme 5)(Scheme 6). To install, reverse removal procedure. Ensure brake pad with wear sensor is installed facing center of vehicle body on right front wheel.

Scheme 5

Scheme 5: Removal & Installation
Scheme 5: Removal & Installation

Scheme 6

Scheme 6
Scheme 6

Raise and support vehicle. Remove front wheels. Disconnect brake flexible hose. Plug all brake line openings. Remove caliper pin bolts. Remove caliper from caliper carrier. To install, reverse removal procedure. Tighten caliper pin bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

  1. Raise and support vehicle. Remove front wheels. Remove caliper assembly, and wire aside. See «FRONT DISC BRAKE CALIPER»(ref-163365-S20959462832004062800000) . Mount dial indicator and check rotor runout before removal. See «DISC BRAKE SPECIFICATIONS»(ref-163365-S41272288662004062800000) .
  2. Remove caliper carrier. Install two 8 mm bolts into rotor holes between wheel studs. Alternately tighten bolts to pull rotor from hub. To install, place rotor on hub and reverse removal procedure.
  1. Raise and support vehicle. Disconnect and plug brake lines from LSPV. (Scheme 7) Remove LSPV together with spring. Remove spring from lever.
  2. To install, reverse removal procedure. Apply multipurpose grease to upper and lower joints of coil spring. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-163365-S22806339662004062800000). Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-163365-S17242424222004062800000). Adjust LSPV. See «LOAD SENSING PROPORTIONING VALVE (GRAND VITARA, VITARA & XL-7 WITHOUT ABS)»(ref-163365-S28379540522004062800000) under ADJUSTMENTS.

Scheme 7

Scheme 7
Scheme 7

Removal & Installation (Grand Vitara & XL-7)

  1. Disconnect fluid level switch lead wire at wire harness connector. Clean around master cylinder reservoir cap. Using a syringe, remove brake fluid from reservoir. Disconnect and cap brake lines at master cylinder and ABS actuator (if equipped) and plug ports on master cylinder and ABS actuator (if equipped). Remove mounting nuts attaching master cylinder to brake booster, and remove master cylinder. (Scheme 8)
  2. To install, reverse removal procedure. On Grand Vitara, adjust clearance between brake booster piston rod and master cylinder piston. See «BRAKE BOOSTER PISTON ROD»(ref-163365-S02031724862004062800000) under ADJUSTMENTS. Fill master cylinder reservoir and bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-163365-S17242424222004062800000). Check brake pedal for play. See «BRAKE PEDAL CLEARANCE»(ref-163365-S15570741912004062800000) under ADJUSTMENTS.

Scheme 8

Scheme 8
Scheme 8

Removal & Installation (Vitara)

  1. Disconnect fluid level switch lead wire at wire harness connector. Clean around master cylinder reservoir cap. Using a syringe, remove brake fluid from reservoir.
  2. On models without ABS, remove and cap brake lines from master cylinder and plug master cylinder ports. On models with ABS, remove and cap brake lines from master cylinder and proportioning valve. Remove proportioning valve mounting bolt, and remove proportioning valve from master cylinder. (Scheme 9) On all models, remove mounting nuts attaching master cylinder to brake booster, and remove master cylinder.
  3. To install, reverse removal procedure. Adjust clearance between brake booster piston rod and master cylinder piston. See «BRAKE BOOSTER PISTON ROD»(ref-163365-S02031724862004062800000) under ADJUSTMENTS. Fill master cylinder reservoir and bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-163365-S17242424222004062800000). Check brake pedal for play. See «BRAKE PEDAL CLEARANCE»(ref-163365-S15570741912004062800000) under ADJUSTMENTS.

Scheme 9

Scheme 9
Scheme 9

Master cylinder reservoir is held in grommets on master cylinder with a roll pin or stopper. (Scheme 10)- (Scheme 11). Disconnect fluid level switch lead. Clean around master cylinder reservoir cap. Using a syringe, remove brake fluid from reservoir. Remove roll pin or screw (stopper on XL-7). Remove master cylinder reservoir. To install, reverse removal procedure. On Grand Vitara and Vitara, ensure roll pin is centered when installed. Bleed brake system after installation. See BLEEDING BRAKE SYSTEM.

Scheme 10

Scheme 10: Removal & Installation
Scheme 10: Removal & Installation

Scheme 11

Scheme 11
Scheme 11
  1. On models with ABS, disconnect brake lines from ABS actuator. On all models, remove master cylinder. See «MASTER CYLINDER»(ref-163365-S02611857532004062800000) . Disconnect vacuum hose from power brake booster. Disconnect push rod clevis from brake pedal arm. Remove 4 nuts attaching power brake booster to firewall. Remove power brake booster.
  2. To install, reverse removal procedure. Check and adjust push rod clevis and piston rod. See «BRAKE BOOSTER PUSH ROD (BRAKE PEDAL HEIGHT)»(ref-163365-S04832441492004062800000) and «BRAKE BOOSTER PISTON ROD»(ref-163365-S02031724862004062800000) under ADJUSTMENTS. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(ref-163365-S17242424222004062800000) .

For removal and installation procedures, see MASTER CYLINDER .

  1. Remove brake drum. See «REAR DRUM»(ref-163365-S28851552372004062800000). Remove shoe hold-down springs by turning hold-down pins. (Scheme 12) Remove upper shoe return spring, strut, adjuster, strut spring, adjuster lever and return springs. Remove brake shoes and lower shoe return spring, and disconnect parking brake cable from parking brake shoe lever. Remove parking brake shoe lever from brake shoe. (Scheme 13)
  2. Check springs and thread or ratchet of strut and adjuster for wear, sticking and corrosion. Replace any component identified with an arrow in illustration if rust is present. (Scheme 14) To install, reverse removal procedure. Before installing brake drum, adjust brake shoe-to-drum clearance. See «REAR DRUM»(ref-163365-S28851552372004062800000). Install brake drum. Pump brake pedal 3-10 times to set automatic adjuster. Adjust parking brake. See «PARKING BRAKE»(ref-163365-S17855863272004062800000) under ADJUSTMENTS.

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14
  1. Raise and support vehicle. Remove rear wheel. Ensure parking brake lever is fully released. Remove rear console box screws or parking brake cover and loosen parking brake cable lock nut. Remove brake drum by inserting two 8-mm bolts through holes in front of drum and alternately tightening bolts.
  2. Before installation, adjust brake shoes to allow brake drum installation clearance. On Grand Vitara and Vitara, outer diameter of brake shoes should be 8.638-.8.650" (219.4-219.7 mm). On XL-7, outer diameter of brake shoes should be 9.972-.9.988" (253.3-253.7 mm). On all models, to install reverse removal procedure. Adjust brake shoes and parking brake. See «PARKING BRAKE»(ref-163365-S17855863272004062800000) under ADJUSTMENTS. Pump brake pedal 3-10 times to set automatic adjuster.

Remove brake drum and brake shoes. See REAR DRUM and REAR BRAKE SHOES . Disconnect and plug brake line from wheel cylinder and plug wheel cylinder port. Remove mounting bolts and remove wheel cylinder. On vehicles with a gasket between wheel cylinder and backing plate, inspect and replace if damaged. On all vehicles, to install, reverse removal procedure. Bleed brake system after installation. See BLEEDING BRAKE SYSTEM .

Removal & Installation (Grand Vitara & Vitara)

  1. Remove brake drum. See «REAR DRUM»(ref-163365-S28851552372004062800000) . Drain rear differential fluid. Remove wheel speed sensor, and plug opening if vehicle is equipped with ABS. Ensure wheel speed sensor is kept clean and protected from damage. Remove wheel bearing retainer nuts from rear axle housing.
  2. Ensure clearance exists between rear wheel bearing retainer and parking brake shoe lever. If clearance does not exist, loosen parking brake cable lock nut. Using Wheel Hub Remover (09943-35512) and Slide Hammer (09942-15510 for 2003 models or 09942-15511 for 2004 models), remove rear axle shaft. Use caution when pulling out axle shaft to ensure brake backing plate does not come out with shaft and to prevent damage to upper and lower brake shoe struts and parking brake cable. Axle shafts are different lengths and cannot be interchanged. Left rear axle shaft is 28" (711.5 mm) long and right rear axle shaft is 29.8" (757.5 mm) long.
  3. If only rear axle shaft inner oil seal is being replaced, insert drift or screwdriver into axle shaft bearing retainer hole to hold backing plate in place. Remove rear axle shaft inner oil seal from axle housing. To replace rear axle bearings, continue to next step.
  4. On models with ABS, grind wheel speed sensor rotor until thin enough to break with a chisel without damaging axle shaft. Remove wheel speed sensor rotor. On all models, grind wheel bearing retainer ring in 2 places until thin enough to break with a chisel without damaging axle shaft. Remove wheel bearing retainer ring. Place axle shaft in hydraulic press and press wheel bearing from axle shaft. Remove wheel bearing retainer. Remove old sealant from backing plate and bearing retainer mounting surfaces.
  5. To install, reverse removal procedure. Apply NEW sealant (99000-31110) to backing plate and bearing retainer mounting surfaces and backside of axle shaft inner oil seal before installation. Use NEW wheel bearing retainer ring and wheel speed sensor rotor on models with ABS. DO NOT damage wheel speed sensor rotor teeth or bearing retainer on models with ABS while pressing wheel speed sensor rotor onto axle shaft. Using proper bearing handle and installer, seat NEW inner oil seal in axle housing until it is seated on oil seal protector inside axle housing. Ensure axle shafts are installed in correct location.

Removal & Installation (XL-7)

  1. Remove brake drum. See «REAR DRUM»(ref-163365-S28851552372004062800000) . Drain rear differential fluid. Remove wheel speed sensor, and plug opening if vehicle is equipped with ABS. Remove wheel bearing retainer nuts from rear axle housing.
  2. Ensure clearance exists between rear wheel bearing retainer and parking brake shoe lever. If clearance does not exist, loosen parking brake cable lock nut. Using Wheel Hub Remover (09943-35512) and Slide Hammer (09942-15510 for 2003 models or 09942-15511 for 2004 models), remove rear axle shaft. Use caution when pulling out axle shaft to ensure brake backing plate does not come out with shaft and to prevent damage to upper and lower brake shoe struts and parking brake cable. Axle shafts are different lengths and cannot be interchanged. Left rear axle shaft is 27.6" (702.0 mm) long and right rear axle shaft is 30.3" (771.5 mm) long.
  3. If only rear axle shaft inner oil seal is being replaced, insert drift or screwdriver into axle shaft bearing retainer hole to hold backing plate in place. Remove rear axle shaft inner oil seal from axle housing. To replace rear axle bearings, continue to next step.
  4. Remove circlip from axle shaft. On models with ABS, grind wheel speed sensor rotor until thin enough to break with a chisel without damaging axle shaft. Remove wheel speed sensor rotor. On all models, grind wheel bearing retainer ring in 2 places until thin enough to break with a chisel without damaging axle shaft. Remove wheel bearing retainer ring. Using Bearing Holder (09921-57810) and Puller (09927-18411) remove wheel bearing and retainer from axle shaft. Remove old sealant from backing plate and axle hub mounting surfaces.
  5. To install, reverse removal procedure. Apply NEW sealant (99000-31110) to backing plate and axle hub mounting surfaces and backside of axle shaft inner oil seal before installation. Use NEW wheel bearing retainer ring and wheel speed sensor rotor on models with ABS. DO NOT damage wheel speed sensor rotor teeth or bearing retainer on models with ABS while pressing wheel speed sensor rotor onto axle shaft. Using proper bearing handle and installer, seat NEW inner oil seal in axle housing until it is seated on oil seal protector inside axle housing. Ensure axle shafts are installed in correct location.

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