parking brake SUZUKI SWIFT 2000 1.G RG413 Service User Guide

3E-26 REAR SUSPENSION
2) Remove rear axle shaft oil seal (1) by using special tool.
Special tool
(A) : 09913-50121
INSTALLATION
1) Using special tools, drive in oil seal (1) or (2) until it contacts
oil seal protector (3) in axle housing.
Special tools
(A) : 09924-74510
(B) : 09944-67010
“A” : Grease 99000-25010
2) For procedure hereafter, refer to steps 5) to 7) of “REAR
AXLE SHAFT AND WHEEL BEARING” in this section.
REAR AXLE HOUSING (4WD VEHICLE)
REMOVAL
1) Hoist vehicle.
2) Remove rear axle shaft referring to item 2) to 8) of “REAR
AXLE SHAFT AND WHEEL BEARING” in this section.
3) Disconnect brake pipe from flexible hose and remove E-ring.
4) Remove brake pipe clamps and pipes from axle housing.
5) Remove parking brake cable clamps and disconnect parking
brake cable from axle housing.
6) Remove wheel speed sensor and release clamps from axle
housing (if equipped with ABS).
7) Remove LSPV adjust nut and detach spring end from rear
axle housing (if equipped with LSPV).
2. Axle housing
NOTE:
There are 2 types of oil seal ((1) & (2)). Their shapes are dif-
ferent as shown in the figure but they are both usable.
Special Tool (B) can be used for both oil seals (1) and (2).
Make sure that oil seal is free from inclination as it is
installed.
Refer to the figure to check that oil seal is installed in
proper direction.
CAUTION:
When installing oil seal (2), never hit any part other than
the position indicated as (6) in the figure. Make sure to
use special tools indicated below. Failure to observe this
caution will cause oil seal to be deformed and oil leakage
to occur.
4. Differential side
5. Apply grease here
6. Press-fitting point

REAR SUSPENSION 3E-29
4) Install lateral rod (1) and install bolt (3) in proper direction as
shown. At this time, mount bolt and nut (4) but don’t tighten
them.
5) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 99000-31110
6) Install differential carrier assembly to axle housing and
tighten carrier nuts to specified torque.
Tightening torque
Rear differential carrier nuts : 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Install propeller shaft to joint flange aligning match marks (1)
and tighten flange bolts to specified torque.
Tightening torque
Companion flange bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Install LSPV spring to rear axle.
Tighten LSPV adjust nut temporarily at this step. (if equipped
with LSPV).
9) Install wheel speed sensor and clamp wire securely (right &
left) (if equipped with ABS).
10) Remove floor jack from axle housing.
11) Connect brake pipes and parking brake cable and clamp
them securely.
For clamping positions, refer to Section 5.
12) Connect brake flexible hose to bracket and secure it with E-
ring.
2. Vehicle body
A : Forward

3E-30 REAR SUSPENSION
13) Connect brake pipe to wheel cylinder (1) and tighten brake
pipe flare nut (2) to specified torque.
Tightening torque
Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
14) Clean mating surface of axle housing (2) (right & left) with
brake back plate and apply sealant as shown.
“B” : Sealant 99000-31090
15) Apply grease to axle shaft oil seals (1) lip (right & left) as
shown.
“A” : Grease 99000-25010
16) Install rear axle shaft (right & left) to rear axle housing and
tighten brake back plate bolts to specified torque.
Tightening torque
Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
17) Connect brake pipes (3) to wheel cylinders (1) (right & left)
and tighten brake pipe flare nuts (2) to specified torque.
Tightening torque
Brake pipe flare nuts (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
18) Connect parking brake cable (2) to parking brake shoe lever
(right & left) and secure it with clip (3).
Apply water tight sealant where brake back plate (1) and
parking brake cable contact.
“A” : Sealant 99000-31090
19) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, see Section 5.)
20) Refill differential gear housing with new specified gear oil.
Refer to Section 7F.
NOTE:
Check to ensure that clip is in good condition before
installing it. If deformed or broken, replace.
A : Forward

REAR SUSPENSION 3E-31
21) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts (f) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
22) Upon completion of all jobs, pull parking brake lever with
about 20 kg, (44 lbs) load three to five times so as to obtain
proper drum-to-shoe clearance.
Adjust parking brake cable (for adjustment, see Section 5.)
23) Lower hoist.
24) Tighten right and left trailing arm bolts and nuts (1) and
shock absorber lower bolts (2) to specified torque.
Tighten lateral rod bolt and nut (3) to specified torque.
Tightening torque
Rear trailing arm bolts (a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)
Rear shock absorber lower bolts
(b) : 58 N·m (5.8 kg-m, 42.0 lb-ft)
Lateral rod axle housing side nut
(c) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Lateral rod body side nut (d) : 65 N·m (6.5 kg-m, 47.0 lb-ft)
25) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
26) Perform brake test (foot brake and parking brake).
(For brake test, see Section 5.)
27) If equipped with LSPV, check and adjust LSPV spring refer-
ring to “LSPV INSPECTION AND ADJUSTMENT” and per-
form “FLUID PRESSURE TEST” in Section 5.
28) Check each installed part for oil leakage.
NOTE:
When tightening these bolts and nuts, be sure that vehi-
cle is off hoist and in non loaded condition.

BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
5
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
GENERAL DESCRIPTION ................................ 5-2
DIAGNOSIS ....................................................... 5-4
ROAD TESTING BRAKES ............................. 5-4
BRAKE FLUID LEAKS ................................... 5-4
SUBSTANDARD OR CONTAMINATED
BRAKE FLUID ................................................ 5-4
DIAGNOSIS TABLE ....................................... 5-5
BRAKE PEDAL FREE HEIGHT
ADJUSTMENT ............................................... 5-8
BRAKE PEDAL PLAY INSPECTION ............. 5-8
STOP LIGHT SWITCH ADJUSTMENT.......... 5-8
EXCESSIVE PEDAL TRAVEL
INSPECTION ................................................. 5-9
FRONT BRAKE PAD INSPECTION .............. 5-9
BRAKE DISC INSPECTION........................... 5-9
PARKING BRAKE INSPECTION AND
ADJUSTMENT ............................................. 5-10
BOOSTER OPERATION INSPECTION....... 5-11
FLUID PRESSURE TEST (IF EQUIPPED
WITH LSPV) ................................................ 5-12
MASTER CYLINDER AND BRAKE FLUID
LEVEL INSPECTION ................................... 5-14
BRAKE HOSE AND PIPE INSPECTION ..... 5-15
HOSE ....................................................... 5-15
PIPE ......................................................... 5-15
ON-VEHICLE SERVICE .................................. 5-15AIR BLEEDING OF BRAKE SYSTEM ......... 5-15
FRONT BRAKE ........................................... 5-17
BRAKE PAD............................................. 5-17
CALIPER ASSEMBLY ............................. 5-19
BRAKE DISC ........................................... 5-23
REAR BRAKE .............................................. 5-25
BRAKE DRUM ......................................... 5-26
BRAKE SHOE .......................................... 5-29
WHEEL CYLINDER ................................. 5-30
BRAKE BACK PLATE (FOR 2WD
VEHICLE)................................................. 5-31
BRAKE BACK PLATE (FOR 4WD
VEHICLE)................................................. 5-33
MASTER CYLINDER ................................... 5-33
MASTER CYLINDER RESERVOIR ......... 5-33
MASTER CYLINDER ASSEMBLY........... 5-34
BRAKE BOOSTER ...................................... 5-38
BRAKE HOSE/PIPE .................................... 5-41
FRONT BRAKE HOSE/PIPE ................... 5-41
REAR BRAKE HOSE/PIPE...................... 5-44
PARKING BRAKE CABLE ........................... 5-46
LSPV (LOAD SENSING PROPORTIONING
VALVE) ASSEMBLY (IF EQUIPPED).......... 5-48
REQUIRED SERVICE MATERIAL.................. 5-50
SPECIAL TOOL .............................................. 5-50

NOTE:
All front 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 reassem-
bly to assure proper retention of all parts. There is to be no welding as it may result in extensive dam-
age and weakening of the metal.

5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis-
tons (two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they
make two independent circuits. One connects front right & rear left brakes and the other connects front left &
rear right brakes.
The load sensing proportioning valve (LSPV) or the proportioning valve (P valve) is included in these circuits
between the master cylinder and the rear brake for the vehicle without ABS.
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 brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes are used for both parking and foot brakes.

5-6 BRAKES
Excessive pedal travel
(Pedal stroke too
large)Partial brake system failure Check brake systems and repair as
necessary.
Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
system.
Check warning light. Bleed system
if required.
Air in system (soft/spongy pedal) Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoes Replace brake shoes.
Worn rear brake shoes Replace brake shoes.
Brake locked
(For vehicle equipped
with ABS)Malfunctioning ABS Check system referring to Section
5E1.
Dragging brakes
(A very light drag is
present in all brakes
immediately after
pedal is released)Master cylinder pistons not returning correctly Replace master cylinder.
Restricted brake pipes or hoses Check for soft hoses or damaged
pipes and replace with new hoses
and/or new double-walled steel
brake piping.
Incorrect parking brake adjustment on rear
brakesCheck and adjust to correct specifi-
cations.
Weakened or broken return springs in the brake Replace.
Sluggish parking brake cables or linkage Repair or replace.
Wheel cylinder or caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Pedal pulsation
(Pedal pulsates when
depressed for brak-
ing)Damaged or loose wheel bearings Replace wheel bearings.
Distorted steering knuckle or rear wheel spindle Replace knuckle or rear wheel spin-
dle.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine
disc.
Parallelism between pad and disc not within
specificationsCheck per instructions. If not within
specifications, replace or machine
disc.
Rear drums out of round Check runout.
Repair or replace drum as neces-
sary.
Braking noise
Glazed shoe linings, or foreign matters stuck to
liningsRepair or replace shoe linings.
Worn or distorted shoe linings Replace shoe lining (or pad).
Loose front wheel bearings Replace wheel bearing.
Distorted backing plates or loose mounting
boltsReplace or retighten securing bolts.
Contact wear indicator to brake disc Replace pads. Condition Possible Cause Correction

BRAKES 5-7
Brake warning lamp
lights after engine
startParking brake applied Release parking brake and check
that brake warning lamp turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning lamp circuit faulty Repair circuit.
Malfunctioning EBD system, if equipped with
ABS.Check system referring to Table-E
of Section 5E1.
Brake warning lamp
turns on when brake
is appliedBrake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Insufficient amount of brake fluid Add brake fluid.
Brake warning lamp
fails to turn on even
when parking brake is
appliedBrake warning lamp circuit faulty Replace bulb or repair circuit.
ABS warning lamp
turns on after engine
start (If equipped)Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
turns on when brake
is applied (If
equipped)Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
does not turn on for 2
sec. after ignition
switch has turned ONBulb burnt out Replace bulb.
Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
flashesNew ABS hydraulic unit/control module assem-
bly installed.Perform “ABS Hydraulic Unit Oper-
ation Check”. Condition Possible Cause Correction

5-10 BRAKES
PARKING BRAKE INSPECTION AND
ADJUSTMENT
INSPECTION
Hold center of parking brake lever grip and pull it up with 200 N
(20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches. There should be 4 to 9 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that
ratchet makes while pulling parking brake lever without pressing
its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable referring
to adjustment procedure so as to obtain specified parking brake
store.
ADJUSTMENT
After confirming that above conditions are all satisfied, adjust
parking brake lever stoke by loosening or tightening adjust nut
(1).NOTE:
Check tooth tip of each notch for damage or wear.
If any damage or wear is found, replace parking brake
lever.
NOTE:
Make sure for the following conditions before cable
adjustment.
No air is trapped in brake system.
Brake pedal travel is proper.
Brake pedal has been depressed a few times with
about 100 N (10 kg, 22 lbs) load.
Parking brake lever is pulled up a few times with about
500 N (50 kg, 110 lbs) load.
Rear brake shoes are not worn beyond limit, and self
adjusting mechanism operates properly.
If parking brake lever stroke is less than specification,
loosen adjusting nut (1) as far as end of bolt. Then
depress brake pedal repeatedly with about 300 N (30
kg, 66 lbs) load until adjuster actuator clicking sound
can not be heard from drum brake.
NOTE:
Check brake drum for dragging after adjustment.

BRAKES 5-11
Parking brake stroke (When lever is pulled up at 200 N (20
kg, 44 lbs)
: 4 to 9 notches
BOOSTER OPERATION INSPECTION
There are two ways to perform this inspection, with and without a
tester. Ordinarily, it is possible to roughly determine its condition
without using a tester.
CHECK AIR TIGHTNESS
1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same load as in
ordinary braking and observe pedal travel. If pedal goes
down deep the first time but its travel decreases as it is
depressed the second and more times, air tightness is
obtained.
4) If pedal travel doesn’t change, air tightness isn’t obtained.
CHECK OPERATION
1) With engine stopped, depress brake pedal several times
with the same load and make sure that pedal travel doesn’t
change. NOTE:
For this check, make sure that no air is in hydraulic line.
1. 1st
2. 2nd
3. 3rd
NOTE:
If defective, inspect vacuum lines and sealing parts, and
replace any faulty part.When this has been done, repeat
the entire test.
1. 1st, 2nd, 3rd