Suzuki Grand Vitara JB416 / JB420. Manual - part 203

4C-2 Rear Brakes: 

Repair Instructions

Rear Drum Brake Assembly Components

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16

17

4

2

9

(b)

(c)

7

6

5

3

8

2

10

12

1

13

18

11

(a)

15

14

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1. Brake back plate

9. Shoe return lower spring

17. Rear wheel hub assembly

2. Brake shoe

10. Shoe hold down spring

18. Rear wheel hub housing bolt

3. Parking brake shoe lever

11. Shoe hold down pin

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

4. Push nut

12. Wheel cylinder

: Apply brake fluid to piston cup.

: 7  N

⋅m (0.7 kgf-m, 5.0 lb-ft)

5. Brake adjuster (strut)

13. Wheel cylinder mounting bolt

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

6. Adjuster pawl lever

14. Rear wheel cylinder bleeder plug

: Do not reuse.

7. Adjuster spring

15. Bleeder plug cap

8. Shoe return upper spring

16. Rear brake drum

Rear Brakes:  4C-3

Rear Brake Drum Removal and Installation

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Removal

1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove rear console box and loosen parking brake 

cable adjusting nut (1).

4) Remove brake drum (1) by using 8 mm bolts (2) (2 

pcs).

Installation

1) Before installing brake drum, check outer diameter of 

brake shoes (1). If it is not within value as specified 
below, adjust it to specification by turning adjuster 
(2).

Rear brake shoe outer diameter “a”
253.3 – 253.7 mm (9.961 – 9.980 in.)

2) Install brake drum after making sure that inside of 

brake drum and brake shoes are free from dirt and 
oil.

3) Upon completion of all jobs, depress brake pedal 

with about 30 kg (66 lbs) load 3 to 10 times so as to 
obtain proper drum-to-shoe clearance.
Adjust parking brake cable. For adjustment, refer to 
“Parking Brake Check and Adjustment in Section 
4D”.

4) Install rear console box.
5) Install wheel and tighten wheel nuts to specified 

torque.

Tightening torque
Wheel nut (a):  100 N·m (10.0 kgf-m, 72.5 lb-ft)

6) 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).

2. Brake cable

1

2

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3. Adjuster pawl lever

2

“a”

1

2

3

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(a)

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4C-4 Rear Brakes: 

Rear Brake Drum and Shoe Inspection

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Brake Drum
Inspect brake drum for wear.
If drum inner diameter is exceeds the limit or uneven or 
stepped wear is excessive, replace the drum.

Rear brake drum inner diameter “a”
Standard: 254 mm (10.00 in.)
Limit: 256 mm (10.07 in.)

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 lining wear and it will 
probably be necessary to resurface drum braking 
surface.
If brake linings are slightly worn and drum is grooved, 
drum should be polished with fine emery cloth but should 
no be turned.

NOTE
When drum is removed, visually inspect 
wheel cylinder for brake fluid leakage. 
Correct leaky point, if any.

 

Brake Shoe
Measure the minimum thickness of brake lining (1). Also, 
check surface of lining for hardening, excessive wear 
and oil.

Rear brake shoe lining thickness “a” 
Standard: 4.5 mm (0.18 in.)
Limit: 1.0 mm (0.04 in.)

CAUTION

!

 

Never polish lining with sandpaper. If lining is 
polished with sandpaper, hard particles of 
sandpaper will be deposited in lining and 
may damage drum. When it is required to 
correct lining, replace it with a new one.

 

Rear Brake Shoe On-Vehicle Check

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Inspection should be carried out on the following points 
after brake pedal travel (pedal to silencer clearance) 
check as described on “Excessive Pedal Travel Check in 
Section 4A”, even when it is more than specification.
Amount of brake shoe wear can be checked as follows.

1) Hoist vehicle.
2) Remove rubber plug (1) from brake back plate.
3) Through hole of back plate, visually check for 

thickness of brake shoe lining (2). If lining thickness 
less than specified wear limit, replace with new 
brake shoes.

Lining thickness “a”
Service limit: 1.0 mm (0.04 in.)

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3. Brake shoe rim

“a”

1

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2

3

“a”

2

1

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Rear Brakes:  4C-5

Rear Brake Shoe Removal and Installation

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WARNING

!

 

Use special care when installing brake shoe 
return spring. Failure in its proper installation 
may allow it to springback and cause 
personal injury.

 

Removal

1) Remove brake drum referring to “Rear Brake Drum 

Removal and Installation”.

2) Fully turn adjuster (1) to reduce brake shoe adjuster.

3) Remove shoe hold down springs (1) by turning shoe 

hold down pins (2).

4) Remove upper shoe return spring (1), brake adjuster 

(2), adjuster pawl lever (3) and spring.

5) Remove brake shoes (4) and lower shoe return 

spring (5).

6) Disconnect parking brake shoe lever (1) from 

parking brake cable (2).

7) Remove push nut (1).
8) Remove parking brake shoe lever (2) from brake 

shoe (3).

Installation

1) Assemble parts in reverse order of removal 

procedure.

2) Before install brake shoe, be sure to fully turn brake 

adjuster to reduce.

3) Install shoe hold down springs (1) by pushing them 

down in place and turning hold down pins (2).

2. Adjuster pawl lever

1

2

1

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3

2

4

1

4

5

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2

3

1

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