BRAKE SYSTEM

1992 Suzuki Swift

1991-92 BRAKES
Suzuki Disc & Drum
Samurai, Sidekick, Swift

DESCRIPTION
The hydraulically operated brake system uses a tandem master
cylinder, with a vacuum assisted power brake booster and single
piston, sliding caliper disc brakes. Swift GT has 4-wheel power disc
brakes. Samurai, Sidekick and other Swift models have self-adjusting
rear drum brakes. All models have cable actuated rear parking brakes.

BLEEDING BRAKE SYSTEM

CAUTION:

DO NOT allow brake fluid to contact paint.

Raise and support vehicle. Fill master cylinder reservoir to

maximum mark. Bleed brakes in sequence. See BRAKE LINE BLEEDING
SEQUENCE TABLE. After bleeding brakes, depress brake pedal with a
force equal to an abrupt stop. If sponginess exists, repeat bleeding
procedure.
BRAKE LINE BLEEDING SEQUENCE TABLE

Application

Sequence

Samurai (1991) ................ LF, RF, Proportioning Valve,

Samurai (1992) ................ RF, LF, Proportioning Valve,
Sidekick (1991) ............... LR, Proportioning Valve, LF,
Sidekick (1992) ............... RF, Proportioning Valve, LF,
Swift .......................................... RR, LR, RF,
Swift GT ........................................ RR, LF,LR,

RR
LR
RF
RR
LF
RF

ADJUSTMENTS
PARKING BRAKE

NOTE:

Before adjusting parking brake, ensure pedal height is

correct and brake shoes are not worn beyond limit.

Loosen lock nut on end of parking brake cable. Hold cable nut
to prevent cable from twisting and tighten adjusting nut. Pull parking
brake handle slowly with 44-55 lbs. (20-25 kg) and count clicks. There
should be 3-8 clicks on Samurai, 7-9 clicks on Sidekick and 4-9 clicks
on Swift.

FRONT WHEEL BEARINGS

Samurai
1) Using spring scale attached to wheel stud, measure
starting torque required to rotate rotor. Starting torque should be 2.
2-6.6 lbs. (1-3 kg). If adjustment is required, bend lock washer away
from lock nut. Remove bearing lock nut and lock washer.
2) Using Socket (09941-58010) and ft. lb. torque wrench,
tighten bearing nut to 59 ft. lbs. (80 N.m) while spinning hub
assembly. Loosen bearing nut. Using INCH-pound torque wrench, tighten

bearing nut to 84-115 INCH lbs. (9-13 N.m). Install lock washer and
lock nut. Tighten lock nut to specification. See TORQUE SPECIFICATIONS
TABLE at end of article. Bend tab on lock washer against lock nut.
3) Using spring scale, recheck starting torque. Reverse
removal procedures. Apply Sealing Compound 366E (99000-31090) to hub
and drive axle flange prior to installation (if equipped).
NOTE:

Sidekick and Swift have sealed wheel bearings, which are not
adjustable.

PEDAL HEIGHT & FREE PLAY

1) Start engine. Depress brake pedal several times. Depress
brake pedal with approximately 66 lbs. (30 kg) of load and measure
from top of pedal pad to floorboard. Clearance must not be less than
2.95" (75 mm) on Samurai, 5.12" (130 mm) on Sidekick and 2.36" (60 mm)
on Swift.
2) If clearance is less than specified, check for worn rear
brake shoes, air in brake lines, malfunction of rear brake shoe
adjuster or booster push rod length out of adjustment.
3) On all models, pedal free play should be .04-.31" (1-8
mm). If not, check stoplight switch for proper installation position
and adjust (if necessary).

BRAKE BOOSTER PUSH ROD

Length of brake booster push rod is adjusted to provide zero
clearance between piston rod end and master cylinder piston. Push
piston rod several times to ensure reaction disc is in place. Set
Booster Piston Rod Gauge (09950-98210 or 09950-96010) on master
cylinder, and push pin on gauge until it contacts piston. Turn tool
upside down and place it on booster. Adjust clearance by turning
adjusting bolt of booster piston rod.

STOPLIGHT SWITCH
Loosen switch lock nut. Pull brake pedal up. Adjust switch
position so clearance between end of switch thread and brake pedal
contact is .02-.04" (0.5-1 mm). Tighten lock nut.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS
Removal & Installation (Samurai)
1) Raise and support vehicle. Remove front wheel. Remove
caliper anti-rattle spring. Remove caliper guide pin caps. Remove
caliper guide pins using 6-mm hex wrench. Remove pad protectors.
2) Pull caliper assembly up, and suspend using wire. Remove
brake pads. To depress piston, open bleeder screw and press piston
back into caliper bore. To install, reverse removal procedure. Bleed
brake system (if necessary).
Removal & Installation (Sidekick & Swift)
Raise and support vehicle. Remove caliper pin bolts. Remove
caliper from caliper carrier and suspend with wire. Remove brake pads
and anti-rattle clips. To install, reverse removal procedure. Bleed
brake system (if necessary).

FRONT DISC BRAKE CALIPER

Removal & Installation (Samurai)

1) Raise and support vehicle. Remove front wheel. Remove
caliper anti-rattle spring. Remove pad protectors. Remove caliper
guide pin caps. Remove caliper guide pins.
2) Pull caliper assembly up and disconnect brake line. Plug
all line openings. To install, reverse removal procedure and bleed
system.
Removal & Installation (Sidekick & Swift)
Raise and support vehicle. Remove front wheel. Remove caliper
pin bolts. Remove caliper from caliper carrier. Disconnect brake
flexhose. Plug all line openings. To install, reverse removal
procedure.

FRONT ROTOR
Removal & Installation
1) Raise and support vehicle. Remove front wheel. Remove
caliper and suspend with wire. Mount dial indicator and check rotor
runout before removal. Maximum runout is .006" (.15 mm).
2) Remove caliper carrier. Install two 8-mm bolts into rotor
holes between wheel studs. On Swift, remove screws before installing
8-mm bolts. Alternately tighten bolts and pull rotor from hub. To
install, place rotor on hub and reverse removal procedure.

REAR DISC BRAKE PADS

Removal & Installation (Swift GT)
1) Raise and support vehicle. Remove rear wheels. Ensure
parking brake is fully released. Remove caliper pin bolts.
2) Remove parking brake cable-to-caliper clip. Disconnect
parking brake cable from caliper. Remove caliper and support with
wire. Remove brake pads.
3) Using Piston Installer (09945-16030), rotate piston
clockwise until fully seated in caliper. Install new brake pads.
Reverse removal procedure to complete installation.

REAR DISC BRAKE CALIPER

Removal & Installation (Swift GT)
1) Raise and support vehicle. Remove rear wheels. Remove
brake flexhose and drain fluid into a container. Release parking brake
lever and remove caliper pin bolts.
2) Remove parking brake cable-to-caliper clip. Disconnect
parking brake cable from caliper lever.
3) To install, reverse removal procedure. Turn caliper piston
counterclockwise to achieve correct brake pad-to-rotor clearance. Fill
and bleed system.

REAR DISC BRAKE ROTOR & HUB

Removal & Installation (Swift GT)
1) Raise and support vehicle. Remove rear wheels. Remove
brake caliper. Remove caliper carrier. Remove rotor screws.
2) Install two 8-mm bolts into rotor holes between wheel
studs. Alternately tighten bolts and pull rotor from hub. Remove
spindle dust cap. Unstake hub nut. Remove hub nut and washer. Discard
hub nut. Use a slide hammer to remove hub.
3) To install, reverse removal procedure. Tighten NEW hub nut
to specification. See TORQUE SPECIFICATIONS TABLE at end of article.

REAR DRUM

Removal & Installation (Samurai & Sidekick)

1) Remove wheel center cap. Loosen, but do not remove, brake
drum nuts and rear wheel lug nuts. Raise rear of vehicle. Remove lug
nuts and rear wheel. Ensure parking brake lever is fully released.
2) To increase clearance between brake shoe and drum, remove
parking brake shoe lever return spring. Disconnect parking brake cable
joint from parking brake shoe lever. Remove parking brake shoe lever
stopper plate. Remove brake drum nuts. Remove brake drum. If drum
sticks, use Slide Hammer (09942-15510) and Adapter (09943-17911).
3) Install brake drum, ensuring grease or oil does not
contaminate brake drum or brake shoes friction surface. Install brake
drum. Install parking brake shoe lever stopper plate. See Fig. 1.
Reverse remainder of removal procedure. Apply brake several times to
set self-adjusting mechanism.

Fig. 1: Parking Brake Shoe Lever Stopper (Samurai & Sidekick)

Courtesy of Suzuki of America Corp.
Removal & Installation (Swift, Except GT)
1) Raise and support vehicle. Remove wheel and spindle cap.

Remove spindle nut. Ensure parking brake is fully released. Loosen

adjustment nut on parking brake cable.
2) To increase drum-to-shoe clearance, remove plug from back
side of backing plate. Insert screwdriver into hole until it contacts
shoe hold-down spring. Push screwdriver toward front of vehicle
depressing hold-down spring and releasing tension on parking brake
lever.
3) Remove brake drum. If drum sticks, use Slide Hammer
(09942-15510) and Adapter (09943-17911).
4) Install brake drum using NEW spindle nut. Tighten spindle
nut to specification. See TORQUE SPECIFICATIONS TABLE at end of
article. Install backing plate plug. Adjust parking brake. See PARKING
BRAKE under ADJUSTMENTS.

REAR BRAKE SHOES

Removal & Installation (Samurai & Swift, Except GT)
Remove brake drum. Remove shoe hold-down springs. Remove
brake shoes. Remove brake shoe strut and return springs. Check springs
and brake shoe strut ratchet for wear or damage. To install, reverse
removal procedure. Pump brake pedal several times to set automatic
adjuster.
Removal (Sidekick)
Raise and support vehicle. Remove tire and wheel. Remove 4
brake drum-to-axle nuts. Remove brake drum using Slide Hammer (J 261901) and Remover (J 37781). Pull drum from axle flange. It may be
necessary to loosen brake adjustment before removing drum.
Installation
Maximize shoe-to-drum clearance by placing screwdriver
between rod and ratchet and pushing down on ratchet. Install brake
drums and 4 brake drum-to-axle nuts. Before moving vehicle, apply
brakes firmly 3-5 times to obtain proper brake shoe-to-drum clearance.

REAR WHEEL CYLINDER

Removal & Installation
With brake drum and shoes removed, disconnect hydraulic line
from wheel cylinder. Remove mounting bolts and remove wheel cylinder.
To install, reverse removal procedure.

MASTER CYLINDER
NOTE:

DO NOT permit brake fluid to contact painted surfaces.

Removal & Installation

Disconnect connector at fluid level sensor (if equipped).
Loosen brake lines on master cylinder. Remove 2 nuts and washers
attaching master cylinder to brake booster. Disconnect brake lines
from master cylinder and plug outlet holes. Remove master cylinder. To
install, reverse removal procedure. Bench bleed new master cylinder
and bleed system.

POWER BRAKE BOOSTER

Removal & Installation
1) Remove master cylinder. Disconnect vacuum hose from
booster. Disconnect push rod clevis from brake pedal arm. Remove 4
nuts attaching booster to firewall. Remove booster.
2) To install, reverse removal procedure. Bleed hydraulic
system. Check and adjust push rod clevis measurement from booster

firewall mounting base to brake pedal clevis pin hole. See Fig. 2.

Fig. 2: Adjusting Push Rod Clevis

Courtesy of Suzuki of America Corp.

REAR AXLE & OIL SEAL

Removal & Installation (Samurai & Sidekick)
1) Raise and support vehicle. Remove rear wheels. Remove rear
brake drum. Disconnect brake line from wheel cylinder. Plug line
openings. Remove 4 backing plate-to-rear axle bolts.
2) Using Adapter (09922-66010) and Slide Hammer (0994215510), remove rear axle and backing plate as an assembly. Remove oil
seal from axle housing. To install, reverse removal procedure.

OVERHAUL
FRONT CALIPER
Disassembly
Insert shop towel between caliper piston and pad retainer
arms. Apply low-pressure compressed air through brake line inlet port
to remove piston. Remove piston dust seal. Remove piston seal using a
thin blade. Remove bleeder screw.
Cleaning & Inspection
Clean all parts in clean brake fluid. Inspect bores and
pistons for excessive wear or damage. Replace defective parts. See
Fig. 3.

Fig. 3: Identifying Front Disc Brake Components

Courtesy of Suzuki of America Corp.
Reassembly
Lubricate NEW piston seal with brake fluid. Insert seal into

piston cylinder seal groove. Carefully insert piston into cylinder

using finger pressure. Apply brake fluid to piston and install NEW
dust cover. Install bleeder screw.

REAR CALIPER
Disassembly (Swift GT)
1) Using Piston Installer (09945-16030), rotate piston and
boot counterclockwise to remove. Remove piston seal using a thin
blade.
2) Remove snap ring, outer spring seat, spring and inner
spring seat. Remove screw rod and key plate. Remove return spring,
camshaft lever, camshaft and camshaft boot.
Cleaning & Inspection
Clean all parts in clean brake fluid. Inspect components for
excessive wear or damage. Replace defective parts. Replace all seals
and boots.
Reassembly
1) Lubricate all parts with clean brake fluid. Install boot
in camshaft bore. Install camshaft.
2) Install screw rod and key plate in piston bore. Ensure
screw pin is inserted in camshaft recess.
3) Install piston seal in caliper bore. Using Piston
Installer (09945-16030), slowly rotate piston clockwise on screw rod
until piston is fully installed in caliper bore. Install camshaft
lever and camshaft return spring. See Fig. 4.

Fig. 4: Exploded View of Rear Brake Caliper (Swift GT)

Courtesy of Suzuki of America Corp.

WHEEL CYLINDER

Disassembly
Remove rubber dust boots. Remove piston assembly and expander
spring. Note installed direction for each cup. Remove cups from
piston. Discard boots and cups.
Inspection
Wash all parts in clean brake fluid. Inspect cylinder bore
and pistons for damage. Replace defective parts.
Reassembly
Lubricate bore with brake fluid. Install spring expander.
Place new piston cups on piston with flare facing center of cylinder.
Install piston assemblies into cylinder. See Fig. 5. Press new boots
onto cylinder.

Fig. 5: Identifying Rear Brake Assembly Components (Typical)

Courtesy of Suzuki of America Corp.

MASTER CYLINDER

Disassembly & Reassembly

1) Drain brake fluid from reservoir. Remove reservoir
connecting screw or pin. Remove reservoir. Remove circlip from rear of
cylinder. Apply low-pressure compressed air to rear reservoir fluid
inlet and remove primary piston.
2) Remove piston stopper bolt on bottom side of cylinder.
Apply compressed air to piston stopper bolt hole and remove secondary
piston. Inspect cylinder bore for scores and grooves. Replace master
cylinder assembly if bore damaged.
3) To reassemble, reverse disassembly procedure using new
internal parts. See Fig. 6.

Fig. 6: Identifying Master Cylinder Components (Typical)

Courtesy of Suzuki of America Corp.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE

Application

Ft. Lbs. (N.m)

Backing Plate Nut ............................... 14-20 (19-27)

Brake Hose Bolt ................................. 15-18 (20-24)
Brake Line Flare Nut ............................ 10-13 (14-18)
Caliper Carrier Bolt ............................ 51-72 (69-98)
Caliper Guide Pin ............................... 19-22 (26-30)
Hub Nut (Swift) ............................. 111-148 (150-200)
Rear Spindle Nut (Swift) ....................... 59-89 (80-120)
Wheel Bearing Lock Nut ................................ 65 (88)
Wheel Nut (1991) ................................ 37-59 (50-80)
Wheel Lug Nut (1992)
Samurai ....................................... 58-80 (79-108)
Sidekick ...................................... 59-80 (80-108)

Swift

..........................................

37-51 (50-69)
INCH Lbs. (N.m)

Brake Booster Mounting Nut ..................... 89-142 (10-16)

Master Cylinder Nut ............................ 89-142 (10-16)
Master Cylinder Stopper Bolt .................... 71-106 (8-12)

DISC & DRUM BRAKE SPECIFICATIONS

DISC & DRUM BRAKE SPECIFICATIONS TABLE

Application

In. (mm)

Samurai & Sidekick

Disc Maximum Lateral Runout ...................... .006 (.15)
Disc Thickness (Solid Rotor) ...................... .392 (10)
Discard Thickness (Solid Rotor) .................. .315 (8.0)
Disc Thickness (Vented Rotor) ..................... .667 (17)
Discard Thickness (Vented Rotor) .................. .590 (15)
Drum Diameter .................................... 8.66 (220)
Drum Discard Diameter ............................ 8.74 (222)
Pad Discard Thickness (1) ......................... .24 (6.0)
Shoe Discard Thickness (1) ........................ .12 (3.0)
Swift
Disc Maximum Lateral Runout ...................... .004 (.10)
Disc Thickness
Front ........................................... .73 (18.5)
Rear .............................................. .39 (10)
Disc Discard Thickness
Front ........................................... .65 (16.5)
Rear ............................................. .32 (8.0)
Drum Diameter .................................... 7.09 (180)
Drum Discard Diameter ............................ 7.16 (182)
Pad Discard Thickness
Front
(1) ...................................... .32 (8.0)
Rear
(1) ....................................... .24 (6.0)
Shoe Discard Thickness
(1) ...................... .11 (2.8)
(1) - Thickness includes pad/shoe and backing material.