Get Brakes -> Rear Drum Brake Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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.

10. Rubber plug

11. Wheel cylinder bolt

: Tightening Torque

: Do not reuse

BRAKES 5-23

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).

5-24 BRAKES

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)

BRAKES 5-25

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.

5-26 BRAKES

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.

BRAKES 5-27

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.

5-28 BRAKES

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.

BRAKES 5-29

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)

5-30 BRAKES

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.

BRAKES 5-31

Brakes -> Rear Drum Brake for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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