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Home >> Suzuki >> 1987 >> Samurai Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 56 (Brakes - Front) >> Repair Instructions >> Front Disc Brake Mounting and Hardware Inspection
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Front Disc Brake Mounting and Hardware Inspection

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
  2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  4. Install a large C-clamp (1), over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    5. Fig 1: Installing Large C-Clamp (1) Over Body Of Brake Caliper (2)
    G04843877Courtesy of SUZUKI OF AMERICA CORP.
  5. Tighten the C-clamp (1) until the caliper piston is compressed into the caliper bore leaving a gap of approximately 10 mm (0.38 in) between the disc brake pads and the brake rotor.
  6. Remove the C-clamp (1) from the caliper (2).
  7. Grasp the brake caliper and attempt to move the brake caliper vertically. The brake caliper should not exhibit excessive looseness.
  8. Grasp the brake caliper and move the brake caliper inboard and outboard. The brake caliper should slide smoothly with minimal force.
  9. Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket (5), yet slide easily on the mounting hardware without binding.
  10. Inspect the disc brake pad mounting hardware, pad retainers (7), for the following:
    • Bent mounting tabs
    • Excessive corrosion
    • Looseness at the brake caliper mounting bracket
    • Excessive wear and/or looseness at the disc brake pads
    • Missing mounting hardware
      • Fig 2: Identifying Brake Caliper Components
      G04843878Courtesy of SUZUKI OF AMERICA CORP.
  11. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
  12. Inspect the brake caliper guide pins (2) by gently pushing inward, without disengaging the slides from the boots, then pull outward, and observe for the following:
    • Bent or damaged brake caliper bolts (1)
    • Restricted caliper guide pin movement
    • Corrosion
    • Split or torn boots (4)
    • Missing boots
    • Looseness in the brake caliper mounting bracket
    • Seized or binding caliper guide pins
  13. If any of the conditions listed are found, the brake caliper mounting hardware requires replacement.
  14. Inspect the brake caliper mounting bracket (5) for being bent, cracked, or damaged.
  15. If any of the conditions listed are found, the brake caliper mounting bracket requires replacement.
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