Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 275

4C-3 Rear Brakes: 

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:  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).

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.

 

3. Adjuster pawl lever

2

“a”

1

2

3

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Rear Brakes:  4C-4

Brake Shoe

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.

 

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.)

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.)

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).

3. Brake shoe rim

“a”

1

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2

3

“a”

2

1

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2. Adjuster pawl lever

1

2

1

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3

2

4

1

4

5

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4C-5 Rear Brakes: 

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 installing rear brake shoe to brake back plate, 

clean brake back plate and apply High-temperature 
grease to A on which shoe rims rest.

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

adjuster to reduce.

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

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

5) Install brake adjuster (2) and upper shoe return 

spring (1).

6) Install adjuster pawl lever (3) and adjuster spring.

7) For procedure hereafter, refer to “Rear Brake Drum 

Removal and Installation”.

Rear Brake Shoe Inspection

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Parking Brake Shoe Lever
Inspect brake shoe lever for free movement against 
brake shoe web. If defective, correct or replace.

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2

3

1

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A

A

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4. Brake shoe
5. Lower shoe return spring

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3

2

4

1

4

5

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Rear Brakes:  4C-6

Brake Adjuster
Check thread or ratchet of adjuster for wear, sticking and 
corrosion.
If found defective, replace brake adjuster.

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

Brake Shoe
Refer to “Rear Brake Drum and Shoe Inspection”.

Wheel Cylinder Removal and Installation

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Removal

1) Remove brake drum referring to “Rear Brake Drum 

Removal and Installation”.

2) Remove brake shoe referring to “Rear Brake Shoe 

Removal and Installation”.

3) Loosen brake pipe flare nut (1) but only within the 

extent that fluid does not leak.

4) Remove wheel cylinder mounting bolts (2). 

Disconnect brake pipe from wheel cylinder and put 
wheel cylinder bleeder plug cap (3) onto pipe to 
prevent fluid from spilling.

Installation

1) Fit wheel cylinder to brake back plate, take off 

bleeder plug cap from brake pipe and connect pipe 
to wheel cylinder just enough to prevent fluid from 
leaking.

2) Tighten wheel cylinder mounting bolts to brake back 

plate (1) to specified torque.

Tightening torque
Wheel cylinder mounting bolt (a):  13 N·m (1.3 
kgf-m, 9.5 lb-ft)

3) Tighten flare nut of brake pipe (2) to specified torque.

Tightening torque
Brake pipe flare nut (b):  16 N·m (1.6 kgf-m, 12.0 
lb-ft)

4) Install bleeder plug cap (3) taken off from pipe back 

to bleeder plug.

5) Install brake shoe referring to “Rear Brake Shoe 

Removal and Installation”.

6) Install brake drum referring to step 1) to 2) of “Rear 

Brake Drum Removal and Installation”.

7) Fill reservoir with brake fluid and bleed brake 

system. For bleeding operation refer to “Air Bleeding 
of Brake System in Section 4A”.

8) Adjust, check brake and install rear wheel referring 

to step 3) to 6) of “Rear Brake Drum Removal and 
Installation”.

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3

2

1

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2

(b)

3

(a)

1

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