BRAKES 5-1

SECTION 5

BRAKES
NOTE:
All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening
of the metal.

CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . 5- 2 Brake Hose and Pipe Inspection . . . . . . . . . 5-10
Front Disc Brake Caliper Assembly . . . . . . . 5- 3 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . 5-11
Rear Drum Brake Assembly . . . . . . . . . . . . . 5- 3 Brake Hose/Pipe and Parking Brake
Master Cylinder Assembly . . . . . . . . . . . . . . 5- 3 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4 FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . 5-15
Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . . 5- 5 Brake Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . 5-18
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 5- 7 Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Brake pedal Free Height Adjustment . . . . . 5- 7 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 5-23
Brake Pedal Play Inspection . . . . . . . . . . . . . 5- 7 Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5
Stop Light Switch Adjustment . . . . . . . . . . . . 5- 7 Brake Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Excessive Pedal Travel Check . . . . . . . . . . . 5- 7 Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Front Brake Pad Inspection . . . . . . . . . . . . . 5- 8 Brake Back Plate . . . . . . . . . . . . . . . . . . . . . . 5-30
Brake Disc Inspection . . . . . . . . . . . . . . . . . . 5- 8 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 5-32
Rear Drum Brake Shoe Adjustment . . . . . . 5- 8 Master Cylinder Reservoir . . . . . . . . . . . . . . . 5-32
Parking Brake Inspection and Master Cylinder Assembly . . . . . . . . . . . . . . 5-33
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 9
Flushing Brake Hydraulic System . . . . . . . . 5- 9 REQUIRED SERVICE MATERIALS . . . . . . . . 5-37
Master Cylinder and Brake Fluid SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Level Inspection . . . . . . . . . . . . . . . . . . . . . . 5-10
5-2 BRAKES

GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Four brake pipes are connected to the master cylinder and they
make two independent circuits. One connects the front right & rear left brakes and the other connects the front left
& rear right brakes.
The proportioning valve (P valve) is included in these circuits between the master cylinder and rear wheels.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading/trailing
shoes) for the rear wheel brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-
chanical linkage system. The same brake shoes are used for both parking and foot brakes.

1. Master cylinder
2. Proportioning valve
3. Parking brake lever
4. Disc brake
5. Drum brake
 BRAKES 5-3

FRONT DISC BRAKE CALIPER ASSEMBLY

This caliper has a single 51.1 mm (2.012 in.) bore and is mounted to the brake caliper holder with two mounting
bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hy-
draulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to
move (slide) the caliper inward, resulting in a clamping action on the disc. This clamping action forces the pads
(linings) against the disc, creating friction to stop the vehicle.

NOTE:
Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo-
nents may result. If any component is removed or line disconnected, bleed the brake system. Replace pads
in axle sets only. The torque values specified are for dry, unlubricated fasteners.

REAR DRUM BRAKE ASSEMBLY

The drum brake assembly has a self shoe clearance adjusting system so that drum- to-shoe clearance is main-
tained appropriate at all times.
NOTE:
Replace all components included in repair kits used to service this drum brake. Lubricate parts as speci-
fied.

WARNING:
When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by
cleaning wheel brake parts with a dry brush or with compressed air. (A water dampened cloth should
be used.) Many wheel brake parts contain asbestos fibers which can become airborne if dust is
created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm.
If any hydraulic component is removed or brake line disconnected, bleed the brake system. The
torque values specified are for dry, unlubricated fasteners.

MASTER CYLINDER ASSEMBLY

The tandem master cylinder is similar in construction to an ordinary master cylinder, the principal differences being
that it has two pistons and that hydraulic pressure is developed in two chambers, one for front left & rear right brakes
and the other for front right & rear left brakes.

1. Master cylinder body 5. Stopper bolt seal ring

2. Master primary piston 6. Push rod
3. Master secondary piston 7. Piston stopper circlip “A” : Primary piston (For front left & rear right brakes)
4. Piston stopper bolt 8. Master cylinder boot “B” : Secondary piston (For front right & rear left brakes)
5-4 BRAKES

DIAGNOSIS
ROAD TESTING BRAKES SUBSTANDARD OR CONTAMINATED BRAKE
Brakes should be tested on dry, clean, smooth and FLUID
reasonably level roadway which is not crowned. Road Improper brake fluid, mineral oil or water in the fluid
test brakes by making brake applications with both may cause brake fluid to boil or rubber components
light and heavy pedal forces at various speeds to de- in the hydraulic system to deteriorate.
termine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the If primary piston cups are swollen, then rubber parts
other without brake application. If it does, check the have deteriorated. This deterioration may also be evi-
tire pressure, front end alignment and front suspen- denced by swollen wheel cylinder piston cups on the
sion attachments for looseness. See diagnosis table drum brake wheels.
for other causes.
If deterioration of rubber is evident, disassemble all
BRAKE FLUID LEAKS hydraulic parts and wash with alcohol. Dry these parts
Check the master cylinder fluid levels. While a slight with compressed air before assembly to keep alcohol
drop in reservoir level does result from normal lining out of the system. Replace all rubber parts in the sys-
wear, an abnormally low level indicates a leak in the tem, including hoses. Also, when working on the
system. In such a case, check the entire brake system brake mechanisms, check for fluid on the linings. If ex-
for leakage. If even a slight evidence of leakage is cessive fluid is found, replace the pads or linings.
noted, the cause should be corrected or defective
parts should be replaced. If master cylinder piston seals are satisfactory, check
for leakage or excessive heat conditions. If leakage
is not found, drain fluid, flush with brake fluid, refill and
bleed system.

The system must be flushed if there is any doubt as

to the grade of fluid in the system or if fluid has been
used which contained parts that have been subjected
to contaminated fluid.
 BRAKES 5-5

DIAGNOSIS TABLE
Condition Possible Cause Correction
Not enough D Brake oil leakage from brake lines. Locate leaking point and repair.
braking force D Brake disc or pads stained with oil. Clean or replace.
D Overheated brakes. Determine cause and repair.
D Poor contact of shoes on brake drum. Repair for proper contact.
D Brake shoes linings stained with oil or wet with Replace.
water.
D Badly worn brake pad linings. Replace.
D Defective wheel cylinders. Repair or replace.
D Malfunctioning caliper assembly. Repair or replace.
D Air in system. Bleed system.
Brake pull D Pad linings and/or shoe linings are wet with wa- Replace.
(Brakes not ter or stained with oil in some brakes.
working in D Drum-to-shoe clearance out of adjustment in Check for inoperative auto adjusting
unison) some brakes. mechanism.
(Malfunctioning auto adjusting mechanism)
D Disc and/or drum is out of round in some Replace.
brakes.
D Wheel tires are inflated unequally. Inflate equally.
D Malfunction in wheel cylinders. Repair or replace.
D Disturbed front end alignment. Adjust as prescribed.
D Unmatched tires on same axle. Tires with approximately the same
amount of tread should be used on the
same axle.
D Restricted brake pipes or hoses. Check for soft hoses and damaged lines.
Replace with new hoses and new brake
piping.
D Malfunctioning caliper assembly. Check for stuck or sluggish pistons and
proper lubrication of caliper slide bush.
Caliper should slide.
D Loose suspension parts. Check all suspension mountings.
D Loose calipers. Check and torque bolts to specifications.
Noise (high D Front lining worn out. Replace linings.
pitched squeak
without brake
applied)
Excessive D Partial brake system failure. Check brake systems and repair as nec-
pedal travel essary.
(Pedal stroke D Insufficient fluid in master cylinder reservoirs. Fill reservoirs with approved brake fluid.
too large) Check for leaks and air in brake system.
Check warning light. Bleed system if re-
quired.
D Air in system (soft/spongy pedal). Bleed system.
D Rear brake system not adjusted Repair auto adjusting mechanism.
(malfunctioning auto adjusting mechanism). Adjust rear brakes.
D Bent brake shoes. Replace brake shoes.
D Worn rear brake shoes. Replace brake shoes.
5-6 BRAKES

Condition Possible Cause Correction

Dragging D Master cylinder pistons not returning correctly. Repair master cylinder.
brakes D Restricted brake pipes or hoses. Check for soft hoses or damaged pipes
(A very light and replace with new hoses and/or new
drag is present brake piping.
in all brakes D Incorrect parking brake adjustment on rear Check and adjust to correct specifications.
immediately brakes.
after pedal is D Weakened or broken return springs in the Replace.
released) brake.
D Sluggish parking brake cables or linkage. Repair or replace.
D Wheel cylinder or caliper piston sticking. Repair as necessary.
D Badly worn piston seal in caliper. Replace piston seal.
Pedal pulsation D Damaged or loose wheel bearings. Replace wheel bearings.
(Pedal pulsates D Distorted steering knuckle or rear wheel Replace knuckle or rear wheel spindle.
when spindle.
depressed for D Excessive disc lateral runout. Check per instructions. If not within speci-
braking) fications, replace or machine disc.
D Parallelism not within specifications. Check per instructions. If not within speci-
fications, replace or machine disc.
D Rear drums out of round. Check runout.
Repair or replace drum as necessary.
Braking noise D Glazed shoe linings, or foreign matters stuck to Repair or replace shoe linings.
linings.
D Worn or distorted shoe linings. Replace shoe linings (or pads).
D Loose front wheel bearings. Replace wheel bearing.
D Distorted backing plates or loose mounting Replace or retighten securing bolts.
bolts.
 BRAKES 5-7

ON-VEHICLE SERVICE
BRAKE PEDAL FREE HEIGHT ADJUSTMENT
Brake pedal height is normal if brake pedal is as high as clutch ped-
al.
When stop light switch has been removed, refer to the following
STOP LIGHT SWITCH ADJUSTMENT for proper installation.

BRAKE PEDAL PLAY INSPECTION

Pedal play should be within below specification.
If out of specification, check stop light switch for proper installation
position and adjust if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Pedal play “a”: 1 – 8 mm (0.04 – 0.31 in.)

STOP LIGHT SWITCH ADJUSTMENT

Adjustment should be made as follows when installing switch (3).
Pull up brake pedal (1) toward you and while holding it there, adjust
switch position so that clearance between the end of thread and
brake pedal contact plate (2) (shown as “b” in figure) is within 0.5
– 1.0 mm (0.02 – 0.04 in.). Then tighten lock nut (4) to specified
torque.
Clearance “b”: 0.5 – 1.0 mm (0.02 – 0.04 in.)
Tightening Torque
(a) : 13 N·m (1.3 kg-m, 9.5 lb-ft)

EXCESSIVE PEDAL TRAVEL CHECK

1) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal arm to wall clearance “c”. It mustn’t be less
than 85 mm (3.35 in.).
Clearance “c”: Over 85 mm (3.35 in.)
2) If clearance “c” is less than 85 mm (3.35 in.), the most possible
cause is either rear brake shoes are worn out beyond limit or air
is in lines.
Should clearance “c” remain less than 85 mm (3.35 in.) even af-
ter replacement of brake shoes and bleeding of system, other
possible but infrequent cause is malfunction of rear brake shoe
adjusters.
D Bleed brake system. (Refer to BLEEDING BRAKES in this
section.)
D Remove brake drums for adjuster inspection. (Refer to
BRAKE DRUM in this section.) If defective, correct or re-
place.
5-8 BRAKES

FRONT BRAKE PAD INSPECTION

Inspect pad linings (1) periodically according to maintenance
schedule whenever wheels are removed (for tire rotation or other
reason). Take a look through each end (or hole) of caliper and
check lining thickness of outside and inside pads.
If lining is worn and its thickness (“d”) in figure is less than limit, all
pads must be replaced at the same time.
Pad thickness “d” (Lining thickness)
Standard : 10.0 mm (0.394 in.)
Limit : 1.0 mm (0.039 in.) for pad rim is painted black
3.0 mm (0.118 in.) for pad rim is painted brown

BRAKE DISC INSPECTION

Refer to BRAKE DISC of this section for inspection point and pro-
cedure.

REAR DRUM BRAKE SHOE ADJUSTMENT

Rear brake has self-adjusting mechanism but it does require ad-
justment for proper drum-to-shoe clearance when brake shoe has
been replaced or brake drum has been removed for some other
service.
Adjustment is automatically accomplished by depressing brake
pedal 2 to 3 times with approximately 30 kg (66 lbs) load after all
parts are installed.
Then check brake drum for dragging and brake system for proper
performance. After lowering vehicle from lift, brake test should be
performed.
 BRAKES 5-9

PARKING BRAKE INSPECTION AND AD-

JUSTMENT
INSPECTION
Hold center or parking brake lever grip and pull it up with 20 to 25
kg (44 to 55f lbs) force.
With parking brake lever pulled up as above, count ratchet notches
in “A” as shown in figure.
There should be 3 to 6 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that ratch-
et makes while pulling parking brake lever without pressing its but-
ton. One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable by referring
to adjustment procedure described on the following so as to obtain
specified parking brake stroke.
NOTE:
Check tooth tip of each notch for damage or wear. If any dam-
age or wear is found, replace parking brake lever.

ADJUSTMENT
NOTE:
Make sure for following conditions before cable (2) adjust-
ment.
D No air is trapped in brake system.
D Brake pedal travel is proper.
D Brake pedal has been depressed a few times with about 30
kg (66 lbs) load.
D Parking brake lever has been pulled up a few times with
about 20 kg force.
D Rear brake pads are not worn beyond limit.
After confirming that above conditions are all satisfied, adjust park-
ing brake lever (1) stroke by loosening or tightening adjusting nuts
(3). Right and left outer cables should be adjusted equal.
NOTE:
Check brake drum for dragging after adjustment.
Parking brake stroke; when lever is
Within 3 – 6 notches
pulled up at 20 kg (44 lbs)

FLUSHING BRAKE HYDRAULIC SYSTEM

It is recommended that entire hydraulic system be thoroughly
flushed with clean brake fluid whenever new parts are installed in
hydraulic system.
It is also recommended that brake fluid be changed every two
years periodically.
5-10 BRAKES

MASTER CYLINDER AND BRAKE FLUID

LEVEL INSPECTION
1) Check master cylinder and reservoir tank for crack, damage
and brake fluid leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX and MIN marks on
reservoir tank.
NOTE:
Be sure to use particular brake fluid either as indicated on res-
ervoir cap of that vehicle or recommended in owner’s manual
which comes along with that vehicle. Use of any other fluid is
strictly prohibited.
Fluid level should be between MIN and MAX lines marked on
reservoir.
When brake warning light lights sometimes during driving, re-
plenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for leak-
age. Correct leaky points and then refill to specified level.

CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has
been used for mineral oil or a container which is wet from
water. Mineral oil will cause swelling and distortion of
rubber parts in hydraulic brake system and water mixed
into brake fluid will lower fluid boiling point. Keep all fluid
containers capped to prevent contamination.

BRAKE HOSE AND PIPE INSPECTION

HOSE
The flexible hydraulic brake hose, which transmits hydraulic pres-
sure from steel brake line on the body to rear cylinders and to front
calipers, should be inspected at least twice a year. The brake hose
assembly should be checked for road hazard damage, for cracks
and chafing of outer cover, for leaks and blisters. A light and mirror
may be needed for an adequate inspection. If any of the above
conditions are observed on brake hose, it will be necessary to re-
place it.

PIPE
Inspect the pipe for damage, cracks, dents and corrosion. If any de-
fect is found, replace it.
 BRAKES 5-11

BLEEDING BRAKES
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
Left wheel cylinder Left brake caliper
A bleeding operation is necessary to remove air whenever it is
introduced into the hydraulic brake system.
REAR FRONT
The hydraulic lines of this brake system are based on the diagonal
split system. When a brake pipe or hose was disconnected at the
wheel, bleeding operation must be performed at both ends of the
Right wheel cylinder Right brake caliper
line of the removed pipe or hose. When any joint part of the master
cylinder of other joint part between the master cylinder and each
brake (wheel) was removed, the hydraulic brake system must be
bled at all 4 wheel brakes.
NOTE:
Perform bleeding operation starting with wheel cylinder far-
thest from master cylinder and then at front caliper of the
same brake line. Do the same on the other brake line.
1) Fill master cylinder reservoir with brake fluid and keep at least
one-half full of fluid during bleeding operation.

2) Remove bleeder plug cap.

Attach a vinyl tube (1) to the bleeder plug of wheel cylinder, and
insert the other end into a container (2).

3) Depress brake pedal several times, and then while holding it de-
pressed, loosen bleeder plug about one-third to one-half turn.
5-12 BRAKES

4) When the fluid pressure in the cylinder is almost depleted, re-

tighten bleeder plug.
5) Repeat this operation until there are no more air bubbles in hy-
draulic line.
6) When bubbles stop, depress and hold brake pedal and tighten
bleeder plug.
Tightening torque for bleeder plug
FRONT: 8.5 N·m (0.85 kg-m, 6.5 lb-ft)
REAR: 8.5 N·m (0.85 kg-m, 6.5 lb-ft)
7) Then attach bleeder plug cap.

8) After completing bleeding operation, apply fluid pressure to

pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level.
10) Check brake pedal for “sponginess”. If found spongy, repeat
entire procedure of bleeding.
 BRAKES 5-13

BRAKE HOSE/PIPE AND PARKING BRAKE CABLE

REMOVAL
1) Raise and support vehicle properly. Remove tire and wheel.
2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose
or pipe.
3) Remove parking brake cable.
INSTALLATION
1) Install it by reversing removal procedure, noting the following points.
D Install clamps properly referring to figure below.
D Tighten bolts and nuts to specified torque.
2) Upon completion if installation, adjust cable. (Refer to PARKING BRAKE INSPECTION AND ADJUSTMENT
of this section.) Then check brake drum for dragging and brake system for proper performance. After removing
vehicle from hoist, perform brake test and check each installed part for fluid leakage.
Rear suspension for I.T.L. type

1. Parking brake cable:

Apply water tight sealant 366E
99000-31090 where plate and
cable contact.
2. Proportioning valve (P-valve)
3. E-ring
4. From master cylinder primary
to P-valve.
5. From master cylinder second-
ary to P-valve.
6. Brake back plate:
Apply water tight sealant 366E
99000-31090 to mating sur-
faces of brake back plate and
rear axle.
7. Clamp A
8. Clamp B
9. Clamp C
10. Clamp D
11. Clamp E
: Tightening Torque 12. Clamp F
5-14 BRAKES

Rear suspension for DEAD AXLE type

1. Primary side 12. Washer 23. Clamp K

2. Secondary side 13. Clamp A 24. Clamp K (right hand steering vehicle)
3. For right hand steering vehicle 14. Clamp B 25. Clamp K (left hand steering vehicle)
4. For left hand steering vehicle 15. Clamp C 26. Clamp L
5. To right front flexible hose 16. Clamp D 27. Parking brake cable:
6. To left front flexible hose 17. Clamp E Apply water tight sealant 366E
7. 4-way joint (right hand steering vehicle only) 18. Clamp F 99000-31090 where plate and cable contact.
8. 4-way joint (left hand steering vehicle only) 19. Clamp G 28. Brake back plate:
9. proportioning valve (P-valve) 20. Clamp H Apply water tight sealant 366E 99000-31090
10. White mark 21. Clamp I to mating surfaces of brake back and rear
11. E-ring 22. Clamp J axle.
 BRAKES 5-15

FRONT DISC BRAKE

1. Caliper pin bolt 8. Piston seal:

2. Caliper pin: Apply brake fluid.
Apply rubber grease 9. Disc brake piston:
to sliding surface of caliper pin. Apply brake fluid.
3. Boot 10. Cylinder boot
4. Disc brake pad 11. Brake disc
: Tightening Torque
5. Bleeder plug cap 12. Disc bolt
6. Bleeder plug 13. Caliper bolt
: Do not reuse
7. Disc brake caliper (Disc brake cylinder)
5-16 BRAKES

BRAKE PAD
REMOVAL
1) Loosen wheel nuts and with vehicle lifted up, remove wheels.
2) Remove caliper pin bolt (1).

3) Remove caliper (1) from caliper carrier (2).

NOTE:
Hang removed caliper (1) with a wire hook or the like so as
to prevent brake hose from bending and twisting exces-
sively or being pulled.
Don’t operate brake pedal with brake pads removed.
4) Remove brake pads (3).

INSPECTION
Check the pad lining for wear. When the wear exceeds its limit, re-
place with a new one. Timing for pad replacement can be deter-
mined with the line of the groove which is provided on each pad
lining. When it has disappeared, replace with a new one.

CAUTION:
Never polish pad lining with sandpaper. If lining is pol-
ished with sandpaper, hard particles of sandpaper will be
deposited in lining and may damage disc. When pad lin-
ing requires correction, replace it with a new one.

Standard Limit
Pad thickness 6.5 mm
“A”
(lining + 15.5 mm (0.256 in.)
pad rim) (0.610 in.) 8.5 mm
“B”
(0.335 in.)

Data marked with “B” is applicable to only European market.

Distinction
“A” marked brake pad rim is painted black.
“B” marked brake pad rim is painted brown.
NOTE:
When pads are removed, visually inspect caliper for brake
fluid leak. Correct leaky point, if any.
 BRAKES 5-17

INSTALLATION
1) Set brake pad springs (1) and install brake pads (2).

2) Install caliper and tighten caliper pin bolt (1) to specified torque.
Tightening Torque
(a): 27 N·m (2.7 kg-m, 19.5 lb-ft)
3) Tighten wheel temporarily and lower lift.

4) Tighten wheel nuts (1) to specified torque.

Tightening Torque
(b): 55 N·m (5.5 kg-m, 40.0 lb-ft)
5) After completion of installation, check for brake effectiveness.
5-18 BRAKES

CALIPER ASSEMBLY
REMOVAL
1) Loosen wheel nuts and with vehicle lifted up, remove wheels.
2) Remove flexible hose bolt (1) and washer.

CAUTION:
Keep end or disconnected hose in a container (2) so that
brake fluid will not get on vehicle body or floor.

3) Remove caliper pin bolt (1) and remove caliper (2) from caliper
carrier (3).

DISASSEMBLY

CAUTION:
Clean around caliper with brake fluid before disassem-
bly.

1) Remove piston with air blown into flexible hose bolt installation
hole.

WARNING:
Do not apply too highly compressed air which will
cause piston to jump out of cylinder. It should be tak-
en out gradually with moderately compressed air. Do
not place your fingers in front of piston when using
compressed air.

1. Cloth
 BRAKES 5-19

2) Remove piston seal using a thin blade like a thickness gauge,

etc.

CAUTION:
Be careful not to damage inside (bore side) of cylin-
der.

INSPECTION
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage. If defective, re-
place.

Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth re-
turn of piston. In such case, replace rubber seal.
5-20 BRAKES

ASSEMBLY
Assemble parts in reverse order of disassembly, observing follow-
ing instructions.

CAUTION:
D Wash each part cleanly before installation in the same
fluid as the one used in master cylinder reservoir.
D Never use other fluid or thinner.
D Before installing piston and piston seal to cylinder, ap-
ply fluid to them.
D After reassembling brake lines, bleed air from them.
D Install a new piston seal into groove in cylinder se-
curely making sure that it is not twisted.
D Before installing caliper to carrier, install caliper pin (1)
with rubber grease applied into caliper carrier hole
and check for its smooth movement in thrust direc-
tion.

NOTE:
Where temperature gets as low as –30 C in cold weather,
use rubber grease whose viscosity varies very little event
at –40 C (–40 F).

Piston Seal
Piston seal is used to seal piston and cylinder and to adjust clear-
ance between pad and disc.
Replace with a new one at every overhaul. Fit piston seal into
groove in cylinder taking care not to twist it.

Piston and Boot

D Before inserting piston (1) into cylinder, install new boot (2) onto
piston as shown.
 BRAKES 5-21

D Fit boot as it is in figure into boot groove in cylinder with fingers.

D Insert piston into cylinder by hand and fit boot in boot groove in
piston.
D To confirm that boot is fitted in its groove in cylinder properly, pull
piston out of cylinder a little but do not take it all out.
D Insert piston into cylinder by hand.

INSTALLATION
1) Install caliper to caliper carrier.
2) Tighten caliper pin bolt (1) to specified torque.

CAUTION:
Check that pin boot is installed securely.

Tightening Torque
(a): 27 N·m (2.7 kg-m, 19.5 lb-ft)

3) Connect flexible hose and tighten flexible hose bolt to specified

torque.
Tightening Torque
(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)
CAUTION:
D Connect hose without twisting.
D Use new washers.
D After installation, perform air bleeding and check
for brake effectiveness and fluid leakage.
5-22 BRAKES

BRAKE DISC
REMOVAL
Refer to WHEEL HUB, KNUCKLE AND BEARING in Section 3D.

INSPECTION
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and the disc is not defective if these are not seri-
ous. But when there are deep scratches or scratches all over the
surface, replace disc.
When only one side is scratched, polish and correct that side.
Brake disc thickness
Standard : 10.0 mm (0.394 in.)
Limit : 8.0 mm (0.315 in.)

To check disc deflection, measure at 2 points on its periphery and

center with a dial gauge, while rotating the disc.
Limit on disc deflection : 0.15 mm (0.006 in.)
Special Tool
(A) : 09900-20606
(B) : 09900-20701

INSTALLATION
Refer to WHEEL HUB, KNUCKLE AND BEARING in Section 3D.
 BRAKES 5-23

REAR DRUM BRAKE

1. Brake back plate:

Apply water tight sealant 366E 99000-31090
to mating surfaces of brake back plate and rear axle.
2. Brake shoe
3. Shoe return spring
4. Brake strut
5. Shoe return spring
6. Rod spring
7. Shoe hold down spring
8. Shoe hold down pin
9. Wheel cylinder:
Apply brake fluid to wheel cylinder components.
Apply water tight sealant 366E 99000-31090 to
contact surface of wheel cylinder.
: Tightening Torque 10. Rubber plug
11. Wheel cylinder bolt
: Do not reuse
5-24 BRAKES

BRAKE DRUM
REMOVAL
1) With parking brake pulled up, hoist vehicle and remove wheels.
2) Remove spindle cap (1). When removing cap with a chisel, tap
it lightly at about 3 locations using care not to damage seat face
of cap.

3) Remove split pin (1), castle nut (2) and washer (3).

4) Release parking brake lever (1) to cancel rear brake.

5) Loosen parking brake cable lock nuts (2).

FRONT

6) Pull brake drum (1) off by using special tools.

Special Tool
(A) : 09942-15510
(B) : 09943-17912

7) Remove wheel stud bolt (1) by using hydraulic press (2) and
general rod (3).
 BRAKES 5-25

8) Insert new stud in drum hole and rotate it slowly to assure serra-
tions are aligned with those made by replaced bolt.

INSPECTION
Inspect drum for cleanliness. Check its braking surface for wear by
measuring its inside diameter.
Drum inside diameter “a”
Standard : 180 mm (7.09 in.)
Limit : 182 mm (7.17 in.)
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.
Cracked, Scored, or Grooved Drum
A cracked drum is unsafe for further service and must be replaced.
Do not attempt to weld a cracked drum. Smooth up any slight
scores. Heavy or extensive scoring will cause excessive brake lin-
ing wear and it will probably be necessary to resurface drum brak-
ing surface.
If brake linings are slightly worn and drum is grooved, drum should
be polished with fine emery cloth but should not be cut.
NOTE:
When drum is removed, visually inspect wheel cylinder for
brake fluid leak. Correct leaky point, if any.
INSTALLATION
1) Before installing brake drum, check that outer diameter of brake
shoes is shorter than 180 mm (7.08 in.). If it is not so, adjust it
to shorter than 180 mm (7.08 in.) by turning adjuster.

2) Install brake drum (1) after making sure that inside of brake
drum and brake shoes are free from dirt and oil.
3) Install washer and axle castle nut.
4) Tighten castle nut (2) to specified torque.
Tightening Torque
(a) : 100 N·m (10.0 kg-m, 72.5 lb-ft)
5-26 BRAKES

5) Bend split pin (1) securely as shown.

6) Install spindle cap (when installing spindle cap, hammer lightly

several locations on the collar of cap until the collar comes
closely into contact with brake drum) and tighten wheel nuts (1)
to specified torque.
Tightening Torque
(b) : 55 N·m (5.5 kg-m, 40.0 lb-ft)
NOTE:
If fitting part of cap is deformed or damaged or if it is fitted
loosely, replace with new one.
7) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load several times so as to obtain proper drum-to-
shoe clearance.
Adjust parking brake cable (For adjustment, refer to PARKING
BRAKE INSPECTION AND ADJUSTMENT in this section).
8) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist and
perform brake test.
 BRAKES 5-27

BRAKE SHOE
REMOVAL
1) Remove brake drum, refer to BRAKE DRUM in this section.
2) Remove shoe hold down springs by turning shoe hold down
pins as shown.

3) Disconnect parking brake cable (1) from parking brake shoe le-
ver (2) and remove brake shoes.

INSPECTION
Brake Shoe
If lining is worn out beyond service limit, replace shoe.
Brake shoe thickness
Standard : 6.0 mm (0.24 in.)
Limit : 2.6 mm (0.10 in.)
If one of brake linings is worn to or beyond service limit, all linings
must be replaced at the same time.

CAUTION:
Never polish lining with sandpaper. If lining is polished
with sandpaper, hard particles of sandpaper will be de-
posited in lining and may damage drum. When it is re-
quired to correct lining, replace it with a new one.

Parking Shoe Lever

Inspect brake shoe lever for smooth movement along shoe rim. If
defective, correct or replace.
5-28 BRAKES

Springs
Inspect for damage, corrosion or weakening. Inspect each part
with arrow for rust. If found defective, replace.

INSTALLATION
Install parts in reverse other of removal.
D Install shoe hold down springs by pushing down them in place
and turning hold down pins.
D For procedure hereafter, refer to BRAKE DRUM in this section.

WHEEL CYLINDER
REMOVAL
1) Remove brake drum, refer to BRAKE DRUM in this section.
2) Remove brake shoe, refer to BRAKE SHOE in this section.
3) Take out fluid with a syringe or such and disconnect brake pipe
flare nut (1) from wheel cylinder.
4) Remove E-ring (2).

5) Remove wheel cylinder mounting bolts.

And put wheel cylinder breeder plug cap onto pipe to prevent
fluid from spilling.

INSPECTION
When removing brake drum, check wheel cylinder for oil leakage.
If any leakage is found, replace wheel cylinder inner parts.

Inspect wheel cylinder disassembled parts for wear, cracks, corro-

sion or damage.

NOTE:
Clean wheel cylinder components with brake fluid.
 BRAKES 5-29

INSTALLATION
1) Before installing wheel cylinder to back plate, apply water tight
sealant to contact surface of wheel cylinder.
“A”: Sealant 366E 99000-31090

2) Take off breeder plug cap from brake pipe and connect pipe to
wheel cylinder just enough to prevent fluid from leaking.
3) Tighten wheel cylinder to brake back plate (1) to specified
torque.
Tightening Torque
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
4) Torque flare nut (2) of brake pipe which was connected in step
3) to specification.
Tightening Torque
(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
5) Install breeder plug cap taken off pipe back to breather plug.
6) Install E-ring (3) to bracket securely.
7) Install brake shoes, refer to BRAKE SHOE in this section.
8) Install brake drum, refer to BRAKE DRUM in this section.
9) Fill reservoir with brake fluid and bleed brake system, refer to
BLEEDING BRAKES in this section.

10) Upon completion of all jobs, depress brake pedal with about
30kg load two to three times so as to obtain proper drum-to-
shoe clearance.
Adjust parking brake cable, refer to PARKING BRAKE IN-
SPECTION AND ADJUSTMENT in this section.
11) Install wheel and tighten wheel nuts to specified torque.
Tightening torque for wheel nut
55 N·m (5.5 kg-m, 42.0 lb-ft)
12) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
13) Check each installed part for oil leakage.
5-30 BRAKES

BRAKE BACK PLATE

REMOVAL
1) Remove brake drum, refer to BRAKE DRUM in this section.
2) Remove brake shoe, refer to BRAKE SHOE in this section.
3) Remove wheel cylinder, refer to WHEEL CYLINDER in this sec-
tion.
4) Remove parking brake cable securing clip (1) and disconnect
brake cable (2) from brake back plate (3).

5) Remove brake back plate (1) by removing bolts (2).

INSTALLATION
1) Apply water tight sealant to mating surfaces of brake back plate
(1) and rear axle.
“A”: Sealant 366E 99000-31090

2) Install brake back plate to rear axle and tighten back plate bolts
(1) to specified torque.
Tightening Torque
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
 BRAKES 5-31

3) Apply water tight sealant where plate and cable contact, and run
parking cable (1) through brake back plate (2) and secure it with
clip (3).
“A” : Sealant 366E 99000-31090
4) Install wheel cylinder, refer to WHEEL CYLINDER in this sec-
tion.
5) For procedure hereafter, refer to WHEEL CYLINDER in this
section.
5-32 BRAKES

MASTER CYLINDER

1. Reservoir cap
2. Master cylinder reservoir
3. Reservoir bolt
4. Grommet:
Apply brake fluid.
5. Master cylinder body
6. Secondary piston assembly:
Apply brake fluid.
7. Primary piston assembly:
Apply brake fluid.
8. Piston stopper circlip
9. Master cylinder boot
10. Push rod

: Tightening Torque

MASTER CYLINDER RESERVOIR

REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean outside of reservoir (1).
3) Take out fluid with a syringe or such.
4) Remove reservoir connector screw (2).
5) Remove reservoir.
INSTALLATION
1) When using new grommets (3), lubricate them with the same
fluid as the one to fill reservoir (1) with. Then press-fit grommets
to master cylinder.
2) Install reservoir and tighten screws (2) to specified torque.
Tightening Torque
(a) : 2.5 N·m (0.25 kg-m, 2.0 lb-ft)
3) Connect reservoir lead wire at coupler.
4) Fill reservoir with brake fluid.
5) Perform air bleeding, refer to BLEEDING BRAKES in this sec-
tion.
 BRAKES 5-33

MASTER CYLINDER ASSEMBLY

REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean outside of reservoir (1).
3) Take out fluid with a syringe or such.
4) Remove reservoir connector screws (2).
5) Remove reservoir.
6) Disconnect brake pipes (4) from master cylinder (3).

CAUTION:
Do not allow brake fluid to get on painted surfaces.

7) Remove master cylinder push rod split pin and rod pin from
brake pedal arm.
8) Remove attaching nuts (5) and washers.
9) Remove master cylinder.

DISASSEMBLY
1) Remove circlip (1).

2) Remove primary piston by removing piston stopper bolt (1). Be

cautions during removal as primary piston will jump out.

3) Pull out secondary piston by tapping flange with a piece of wood

or something soft.
NOTE:
D Do not drop piston.
D Do not cause any damage to inside of cylinder wall.
5-34 BRAKES

NOTE:
Do not loosen lock nut (1) of push rod. Should it be loosened,
be sure to adjust and secure lock nut at the position within the
measurement “a”. Data in figure does not include gasket
thickness.
Length “a”: 102.0 – 103.0 mm (4.016 – 4.055 in.)

INSPECTION
Inspection all disassembled parts for wear or damage, and replace
parts if necessary.
NOTE:
D Wash disassembled parts with brake fluid.
D Do not reuse piston assembly.
Inspect master cylinder bore for scoring or corrosion. It is best to
replace corroded cylinder. Corrosion can be identified as pits or ex-
cessive roughness.
NOTE:
Polishing bore of master cylinder with cast aluminum body
with anything abrasive is prohibited, as damage to cylinder
bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept from cylinder bore surfaces.

ASSEMBLY

CAUTION:
D Never use any mineral oil such as kerosene and gaso-
line when washing and assembling parts.
D Check inside of cylinder wall, pistons and cup seals
are free from any foreign objects such as dust and dirt
and use case not to cause any damage with a tool dur-
ing assembly.
D Do not drop parts. Do not use any part which has been
dropped.
 BRAKES 5-35

1) Assemble secondary piston as shown in figure.

1. Secondary piston return spring

2. Return spring seat
3. Piston cup
4. Secondary piston
5. Piston pressure cap

2) Install secondary piston assembly into cylinder.

3) Install primary piston in cylinder.
4) Depress using a rod (1), and install circlip (2).

5) Install piston stopper bolt (1) with pistons pushed in all the way
and tighten it to specified torque.
Tightening Torque
(a) : 3 N·m (0.3 kg-m, 2.5 lb-ft)
5-36 BRAKES

INSTALLATION
1) Install master cylinder (3) as shown and tighten attaching nuts
(1) to specified torque.
Tightening Torque
(a) : 13 N·m (1.3 kg-m, 9.5 lb-ft)
2) Install master cylinder push rod to brake pedal and bend split
pin securely.
3) Connect 4 hydraulic lines and tighten flare nuts (4) to specified
torque.
Tightening Torque
(b) : 12 N·m (1.2 kg-m, 9.0 lb-ft)
4) When using new grommets, lubricate them with the same fluid
as the one to fill reservoir (2) with. Then press-fit grommets to
master cylinder.
5) Install reservoir and tighten screws (5) to specified torque.
Tightening Torque
(c) : 2.5 N·m (0.25 kg-m, 2.0 lb-ft)
6) Fill reservoir with specified fluid.
After installing, check brake pedal height, bleed air from system
(Refer to BRAKE PEDAL FREE HEIGHT ADJUSTMENT and
BLEEDING BRAKES in this section.

CAUTION:
D Never use any mineral oil such as kerosene and gaso-
line when washing and assembling parts.
D Check inside of cylinder wall, pistons and cup seals
are free from any foreign objects such as dust and dirt
and use case not to cause any damage with a tool dur-
ing assembly.
D Do not drop parts. Do not use any part which has been
dropped.

Fluid to fill reservoir with is indicated on reservoir cap of the vehicle

with embossed letters or in owner’s manual supplied with the ve-
hicle.
Add fluid up to MAX line.
 BRAKES 5-37

REQUIRED SERVICE MATERIALS

RECOMMENDED
MATERIALS USE
SUZUKI PRODUCT
D To fill master cylinder reservoir.
Brake fluid DOT 3 D To clean and apply to inner parts of master cylinder
caliper and wheel cylinder when they are disassembled.
D To apply to mating surfaces of brake back plate and
rear axle.
SEALING COMPOUND 366E D To apply to mating surfaces of brake back plate and
Water tight sealant
(99000-31090) parking brake cable.
D To apply to mating surface of wheel cylinder and brake
back plate.
rubber grease D To apply to sliding surfaces of caliper pin

SPECIAL TOOLS

09943-17912
09900-20606 09900-20701 09942-15510 Brake drum remover
Dial gauge Magnetic stand Sliding hammer (Front wheel hub remover)