LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 1991 >> Samurai JS >> Repair and Diagnosis >> External Pages >> Different car >> Section 59 (Brakes - Rear) >> Repair Instructions >> Rear Brake Caliper Replacement
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Rear Brake Caliper Replacement

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.
Fig 1: Identifying Rear Brake Caliper Components
G04843901Courtesy of SUZUKI OF AMERICA CORP.
BRAKE PAD SPECIFICATION TABLE

Callout Component Name
WARNING:
Preliminary Procedures 
  1. Raise and support vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  2. Remove tire and wheel. Refer to REMOVAL PROCEDURE .
1 Brake Hose Fitting Bolt
CAUTION: Refer to FASTENER NOTICE .

Tightening torque 
52 N.m (38 lb ft) 
2 Brake Hose Fitting Gasket (Qty: 2)
Tip:  DO NOT reuse the gaskets. Install NEW gaskets.
3 Brake Hose
Tip:  Cap or plug the brake hose to prevent brake fluid leaks and contamination.
4 Brake Caliper Guide Pin Bolt (Qty: 2)
NOTE: Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

Tip:  Hold the brake caliper guide pin stationary while removing and installing the guide pin bolt.
Tightening torque 
Tighten the bolts to 35 N.m (26 lb ft) 
5 Disc Brake Caliper
  1. Bleed the brake system. Refer to HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE) and HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL) .
  2. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  3. Slowly release the brake pedal.
  4. Wait 15 seconds, then repeat steps  2 -  3 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  5. Fill the master cylinder reservoir to the proper level. Refer to MASTER CYLINDER RESERVOIR FILLING .