Suzuki Samurai Rear Drum Brake Shoes

8/9/2019 Suzuki Samurai Rear Drum Brake Shoes

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Suggested Tools:

• Penetrating Oil• Floor Jack• Safety Stands (2)• 19 mm Wheel Lug Nut Wrench

• Brake Cleaner (1 Aerosol Can)

• Large Standard Screwdriver

• Needle Nose Pliers

• Larger Ball Peen Hammer

• Combination Wrench: 10 mm

• Large Dead Blow Hammer

• Sockets: 14,17 & 19 mm

• Brake Parts Lubricant• 10 mm Tubing (Flair Nut) WrenchCAUTION: Safety glasses should beworn at all times when working withvehicles and related tools andequipment.

86-95 Suzuki Samurai Rear Drum Brake Shoes(SKU# SB-RBS)

Instructions also include:

Rear Brake Wheel Cylinder (SKU# SB-SRWC)

SJ413 Rear Drum Brake Hardware Kit (SKU# SB-RBHK)

Installation Instructions

Brake Shoes

Wheel Cylinder

Hardware Kit


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Step 5Remove the wheel center cap by

removing the (1) center bolt using a 14mm socket.

Step 6Remove the wheel assembly byremoving the (5) wheel lug nuts using a19 mm lug wrench or socket.

Step 8Remove the brake drum and set itaside.

Caution - DangerSome brake shoe lining materials contain asbestos. Consequently, the dust created in the brakedrums could have asbestos in it. If this dust becomes airborne and then inhaled by individuals, itcould increase the risk of lung cancer and other reparatory diseases. Therefore, you shouldnever clean brake parts by spraying them with compressed air. Always wash brake parts with asafe liquid and then dispose of the liquid in accordance with state and federal regulations. Usinga respirator is also a good idea to reduce the risk of inhaling harmful asbestos dust.

Brake Drum

Step 7Remove the (4) axle nuts and wheelcenter cap bracket using a 17 mmsocket.

Center Cap

Bracket

WheelCenter Cap


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Tech Tip:Seized brake drums can also beloosened by pounding on them with alarge ball peen (or small sledge)hammer in the locations shown above.

Caution: Do not hit the wheel studs orhub studs as thread damage will resultand the nuts will not thread on properly.

Step 9Clean all brake parts by placing a panunder the brakes and spraying all brakeparts with brake cleaner. If brakes areparticularly dirty you may need to use acleaning brush along with the spray.

Step 10Inspect the drum for cracks, scoring orgrooves. If the drum is cracked, thedrum is unsafe and will need to be

replaced. If scoring is excessive thedrum will need to be replaced. If scoringis minor you may be able to have thedrum machined. Machining should beperformed by a qualified professionalwho will measure the drum before andafter machining to insure it is safe forreuse.

Tech Tip:Seized brake drums can be removed byusing a tool like, or similar to, the onepictured above. If you do not haveaccess to such a tool, move to the nextTech Tip.


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Step 12Check the wheel cylinder for leaks bypealing back the boots in the locationsindicated by the arrows. If fluid leaksout from behind the boot, the wheelcylinder cup seals have failed and thewheel cylinder will need to be replaced.Click HERE to see what is availablethrough Low Range Off-Road.

WheelCylinder

Boots

Step 11Also inspect the drum for excessivewear by measuring the inside diameterof the drum. If the drum measuresgreater than 8.740” it will need to bereplaced.

Note: If you do not have the tools and/ or know-how to measure the drum, werecommend you have it measured by aqualified professional.

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Drum Brake Parts Identification

Rod Spring

Rear Brake Sho

Return Spring B

Return Spring

Wheel Cylinder

Park Brake RodSelf Adjusting Ratchet

Hold Down Spring

Hold Down Pin

Forward Brake Shoe

Front of Vehicle

Figure A

Backing Plate

Brake Shoe Lining

Refer to the illustration below if youare not familiar with brake partnames.


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Step 15Remove the rod spring.

Step 14Using a pair of needle nose pliers,remove return spring B.

Note: Needle nose vice grip pliers workwell here too.

Step 16Remove return spring A.

Brake Shoe Removal

Step 13Inspect all the springs and otherhardware as the shoes are removed. Ifthe springs are stretched, worn orrusted, they should be replaced. ClickHERE to see what is available throughour web site.

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Tech TipA good method of removing andinstalling the hold down spring is to pushwith a large screwdriver in the grooveand turn the hold down pin with theneedle nose pliers.

Step 18Disconnect the rear shoe from the parkbrake rod and set the shoe aside.

Step 19Remove the forward brake shoe in thesame way as the rear brake shoe.

Step 17Remove the rear brake shoe by pushinginward on the brake shoe hold downspring and twisting the hold down pin ! turn. Remove the pin from the rear ofthe backing plate and set it aside.

Push Here

Twist Here


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Step 20Clean the backing plate with a wirebrush.

Wheel Cylinder ReplacementIf you are not replacing the wheel cylinder skip to Step 30.

Step 21Place a pan under the brake bleederscrew and remove the brake bleederscrew using a 10 mm box end wrench.

Note: This step is not required but itmakes the next step easier.

Step 22

Remove the brake line from the wheelcylinder. It is highly recommended thatyou use a tubing wrench (10 mm)instead of an open end wrench for brakeline removal. Using a tubing wrench willreduce the risk of rounding up the flairnut corners.

Step 19 ContinuedForward shoe removed.


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Step 23Remove the Wheel Cylinder byremoving (2) bolts using a 10 mm boxend wrench or socket.

Tech TipIf you are changing the brake fluid let itdrain into a pan. If you are not, you willwant to plug the brake line withsomething to keep the fluid fromdraining out of the system. A piece ofvacuum hose and a golf tee works well.

Wheel CylinderBolts

Step 24 ContinuedWheel cylinder removed.Step 24If the wheel cylinder does not come outeasily (and most do not) it may benecessary to jar it loose with a deadblow hammer.


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Step 25Position the new wheel cylinder asshown.

Step 26While holding the wheel cylinder inplace, install the bolts. Then torque thebolts to 6 to 8.5 ft. lbs.

Step 28Install the brake line to the wheelcylinder and tighten. (10.5 to 13.0 ft.lbs.)

Caution: Brake line flare nuts are easilycross-treaded. You will want to start theflare nut by hand for several turnsbefore using a wrench on it. You mayneed to flex or bend the brake lineslightly to get the fitting to align andthread properly.

Step 27Remove the plug and bleeder screw.

Note: It is not required that you removethe bleeder screw. But, it makes

installing the brake line easier.

Plug

Bleeder Screw


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Step 29Reinstall and tighten the brake bleederscrew.

Brake Shoe Installation

Step 31Install the forward shoe hold down pinfrom the rear of the backing plate.

Step 30Lube the backing plate bosses with agood quality brake parts lubricant in the(6) locations shown above.

Tech TipBleeding brake systems typically takes

two people and requires quite a bit oftime. But, with Russell Speed Bleeders,brake system bleeding requires only1one person and goes a lot faster. ClickHERE for more information on this timesaving product.

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Step 32Position the forward brake shoe asshown.

Note: Be sure the park brake rod isfitted properly in the top of the shoe.

Step 33Depress the brake shoe hold downspring, twist the hold down pin ! turnand then release the spring.

Step 35Position the rear brake shoe as shown.Step 34Install the rear shoe hold down pin fromthe rear of the backing plate.


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Step 37Install the return spring B.Step 36Depress the brake shoe hold downspring, twist the hold down pin ! turnand then release the spring.

Step 38

Install the rod spring.

Step 39Be sure the self-adjusting ratchet is at

its smallest setting. This means theratchet should be positioned as shown.

Ratchet


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Tech TipThis is what the brake shoes shouldlook like when properly installed.

Step 40Install return spring A.

Step 41Install the brake drum.

Tech TipIf the drum will not fit over the shoes,check to see that the shoes are in their

proper position. If the drum is still notfitting, check to see that the selfadjusting ratchet is adjusted to its lowestsetting (See Figure B). If the drum stillwill not fit, you may need to open thebleeder screw, force the shoes together,and close the bleeder screw.

Figure B

Self adjusting ratchet at its lowest setting.


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Step 43

Install the wheel assembly and torquethe wheel lug nuts. (36.5 to 57.5 ft. lbs.)

Step 42Install the center cap bracket and axle

hub nuts and torque. (36 to 57.5 ft. lbs.)

Step 45Repeat procedures on the passengerside wheel as needed.

Step 44Install the wheel center cap and tightenthe bolt.


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Step 46Danger: If the wheel cylinders wereremoved for any reason, the brake lines

were disconnected. This means there isair in the brake hydraulic system and thebrakes will NOT work. Therefore, it isEXTREMELY IMPORTANT to bleed thebrake system before moving thisvehicle. Brake Bleeding instructions canbe found in our “Instruction Library” atwww.lowrangeoffroad.com

Note: It is also possible for air to enterthe hydraulic system during a routine

drum brake shoe remove and replaceprocedure. Therefore we recommenddoing a brake system bleed aftercompleting ANY brake system work.

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As always, If you experience any difficulty during the installation of this productplease contact Low Range Off-Road Technical Support at 801-805-6644 M-F8am-5pm MST. Thank you for purchasing from Low Range Off-Road.

These instructions are designed as a general installation guide. Installation of many Low RangeOff-Road products require specialized skills such as metal fabrication, welding and mechanicaltrouble shooting. If you have any questions or are unsure about how to proceed, please contactour shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools suchas welders, torches and grinders can cause serious bodily harm and death. Please operateequipment carefully and observe proper safety procedures.

Rock crawling and off-road driving are inherently dangerous activities. Some modifications willadversely affect the on-road handling characteristics of your vehicle. All products sold by LowRange Off-Road are sold for off road use only. Any other use or application is the responsibilityof the purchaser and/or user. Some modifications and installation of certain aftermarket parts may

under certain circumstances void your original dealer warranty. Modification of your vehicle maycreate dangerous conditions, which could cause roll-overs resulting in serious bodily injury ordeath. Buyers and users of these products hereby expressly assume all risks associated with anysuch modifications and use.

Revised 010/19/12© Copyright 2012 Low Range Off-Road, LC All Rights Reserved

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Suzuki Samurai Rear Drum Brake Shoes