Modification Of Front Brake Caliper And P & B Valve (TS 5-04 03174)

Publication date: 1970-01-01
Reference number: TS 5-04 03174

MODIFICATION OF FRONT BRAKE CALIPER AND P & B VALVE

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 5-04 03174

MODIFICATION OF THE FRONT BRAKE CALIPER AND PROPORTIONING AND BYPASS (P & B) VALVE

Model(s): 1994 Suzuki Samurai

Bulletin No.: TS 5-04 03174

Division: Automotive

Category: Technical

Section Title: Steering, Brakes and Suspension

CONDITION

Change to the front brake caliper and P & B valve.

CORRECTION

Information supplied in this bulletin is to be used in addition to the 1990-1994 Samurai Supplementary Service Manual (99501-83350-33E), group 3, section 19; and should also be used with the 1988 Samurai Service Manual (99500-83310-33E).

This bulletin is to inform you of the modification of the front brake caliper and P & B (Proportioning & Bypass) valve which has been carried out since December 1993 production. When disassembling and reassembling the late type front brake caliper, please refer to the procedures contained in this bulletin.

EFFECTIVE VIN

JS4JC31C_R4100810

MODIFIED PARTS

Refer to Fig 1 .

Front brake caliper assy.
Front disc brake carrier (Front disc brake mounting)
Disc brake pad set
Shim
Piston and seal set
Piston seal set
Antirattle clip
Pad support #1 plate
Pad support #2 plate
Guide pin
Guide pin sleeve
Guide pin boot
Guide pin cap
Cylinder slide bushing
Bushing dust boot
Dust boot support
Bolt
P & B valve

FRONT DISC BRAKE

REMOVAL

Loosen, but do not remove, front wheel nuts.
Hoist vehicle.
Remove wheel nuts and take off front wheels.

BRAKE PAD

After taking down the wheel, remove brake pads according to the following procedure:

Remove caliper bolts. See Fig 2 .
Remove caliper assembly.
NOTE: Hang removed caliper assembly with a wire hook so as to prevent the brake hose from bending and twisting excessively or being pulled. See Fig 3 . Don't operate the brake pedal with pads removed.
Remove pads. See Fig 3 .

CALIPER

After taking down the wheel, remove and disassemble the caliper according to the following procedure:

Clean the outside of the master cylinder.
Take out fluid with a syringe or such.
Wipe caliper clean.
Disconnect brake flexible hose from caliper body. See Fig 4 .
Remove caliper and bolt. For removal of caliper and pads, refer to steps 1) through 3) of brake pad removal in this section.
Remove cylinder boot set ring and boot from cylinder groove. See Fig 5 .
Blow compressed air into cylinder through bolt hole where flexible hose was fitted. With this air pressure, the piston can be pushed out of the cylinder. See Fig 6 .
WARNING: Do not apply high pressure which will cause the piston to jump out of the cylinder. It should be taken out gradually with moderate air pressure. Do not place your fingers in front of the piston when using compressed air to push it
Remove piston seal using a thin blade like a thickness gauge, etc. See Fig 7 .

CAUTION: Be careful not to damage e inside bore of the cylinder.

DISC

After removing the tire, remove the caliper assembly by removing the two carrier bolts. See Fig 8 .
CAUTION: During removal, be careful not to damage the flexible brake hose or depress the brake pedal.
Remove the disc by using 2-8 mm bolts. See Fig 9 .

INSPECTION OF COMPONENTS

BRAKE PAD

Check pad lining for wear. See Fig 10 . When wear exceeds its limit, replace pads.

BRAKE PAD THICKNESS CHART

---	Standard	Limit
Pad thickness (lining + pad rim)	15.0 mm (0.590 in.)	8.0 mm (0.315 in.)

CAUTION: Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one.

NOTE: When brake pads are removed, visually inspect the caliper for brake fluid leak. Correct as necessary.

CYLINDER SLIDE BUSHING

Check bushing for smooth movement, as shown in Fig 11 . If defective, replace.

BUSHING DUST BOOT AND CYLINDER BOOT

Check boots for breakage, cracks, or damage. If defective, replace. See Fig 12 .

PISTON SEAL

Excessive or uneven wear of pad lining may indicate unsmooth return of the piston. In this case, replace the rubber seal.

BRAKE DISC

Check the disc surface for scratches on the wear surface. Minor scratches on disc surface noticed at the time of specified inspection or replacement are normal and the disc is not defective. But when there are deep scratches or scratches all over the surface, replace the disc. When only one side is scratched, polish and correct that side.

BRAKE DISC THICKNESS CHART

---	Standard	Limit
Disc thickness See Fig 13 .	10 mm (0.394 in.)	8.0 mm (0.315 in.)

To check disc deflection, install and zero out dial gauge onto the rotor. See Fig 14 . While turning the rotor, note variation from zero and compare with chart below.

Limit on disk deflection ........ 0.15 mm (0.006 in.)

NOTE: Check front wheel bearing for looseness before measurement.

PRECAUTIONS ON INSTALLATION

Reassemble front brakes in the reverse order of disassembly, using care in the following points:

CAUTION: * Wash each part before installation in clean fresh brake fluid or alcohol.

Never use other solvents or thinner
Before installing piston and piston seal to cylinder apply brake fluid to them.
After reassembling brake line, bleed air from lines

PISTON SEAL

The Piston Seal is used to seal the piston and cylinder and to adjust the clearance between the pad and disc. Whenever you rebuild the caliper, always replace this seal. During installation be sure that seal fits properly into groove and is not twisted in any way.

PISTON AND BOOT

Install dust boot before installing the piston. Make sure to install boot in the proper direction, as shown in Fig 15 .

To facilitate installation of the dust boot into the caliper, position the outer end of the piston so that it projects out of the end of the caliper by about 10 mm (0.4 in.). See Fig 16 .

After boot is properly installed, install the boot set ring.

CALIPER

Before installing the caliper to the carrier, make sure that the guide pin inserted into each caliper mounting hole moves freely in each direction. See Fig 17 .

TIGHTENING TORQUES

Fastening Parts	Tightening Torque Nm	Tightening Torque kg-m	Tightening Torque lb-ft
Brake Caliper Bolt	18 - 26	1.8 - 2.6	13.0 - 18.5
Brake caliper air bleeder plug	9 - 13	0.9 - 1.3	7.0 - 9.0

PARTS SUPPLY DATA

PARTS INFORMATION

REF #	PART NAME	EARLY PART NO.	LATE PART NO.	#	EARLY OF SPARE PARTS	INTERCHANGE- ABILITY (O:OK, X:NO)
1	Front Disc brake caliper assembly	(.) 55100-70A20	55100-70A01	2	Both Early And Late	Early -X-> Late Early <-X- Late
2	Front disc brake carrier (mounting)	(*) 55160-70A10	55161- 80000	2	Both Early And Late	Early -X-> Late Early <-X- Late
3	Disc brake pad set	(.) 55200- 83830	55200- 70812	1	Both Early And Late	Early -X-> Late Early <-X- Late
4	Anti noise shim	* 55171- 83300	---	2	Early only	---
5	Piston and seal set	55100- 84811	55830- 60C10	2	Both Early And Late	Early -X-> Late Early <-X- Late
6	Piston seal set	55100- 84820	55100- 82820	2	Both Early And Late	Early -X-> Late Early <-X- Late
7	Antirattle clip	55234- 84230	2				Early Only	---
8	Pad support # 1 plate	---	55234- 60B00	4	Late Only	---
9	Pad support # 2 plate	---	55235- 60B00	4	Late Only	---
10	Guide pin	55191- 84231	---	4	EARLY Only	---
11	Guide pin sleeve	55202- 84230	---	4	EARLY ONLY	---
12	Guide pin boot	55201- 83300	---	4	EARLY ONLY	---
13	Guide pin cap	55203- 83300	---	4	EARLY ONLY	---
14	Cylinder slide bushing	---	55191- 80000	4	---	---
15	Bushing dust boot	---	55201- 80001	8	Late ONLY	---
16	Dust boot support	---	55196- 0002	4	Late ONLY	---
17	Bolt	---	55206- 80000	4	Late ONLY	---
18	P & B valve	51920-82C01	51920- 82C30	1	Both early and late	Early -X-> Late Early <-X- Late
Note: When the part nujmber marked with an (*) has run out of stock the corresponding dot (.) marked part will be supplied insrtead. The Asterisk marked parts is included in the dot marked part.