2000 SUZUKI SWIFT 4WD

REAR SUSPENSION 3E-25
8) Connect brake pipe to wheel cylinder and tighten brake pipe
flare nut to specified torque.
Tightening torque
Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Refill rear axle (differential) housing with new specified gear
oil. Refer to Section 7F for refill.
10) Install brake drum. For details, refer to “BRAKE DRUM” of
Section 5.
11) Connect parking brake cable (1) to parking brake shoe lever.
Secure parking brake cable to brake back plate with clip (2).
Install wheel speed sensor (if equipped with ABS).
12) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “BLEEDING BRAKES” in Sec-
tion 5.)
13) Install wheel and tighten wheel nuts to specified torque.
14) 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, refer to “PARK-
ING BRAKE INSPECTION AND ADJUSTMENT” in Section
5).
15) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
16) Perform brake test (foot brake and parking brake).
(For brake test, see Section 5.)
17) Check each installed part for oil leakage.
REAR AXLE SHAFT OIL SEAL (4WD VEHI-
CLE)
REMOVAL
1) Remove rear axle shaft. For details, refer to steps 1) to 8) of
“REAR AXLE SHAFT AND WHEEL BEARING” in this sec-
tion.
CAUTION:
Check to ensure that clip is in good condition before
installing it. If deformed or broken, replace.
1. Plug cap
2. Vinyl tube (See-through tube)
3. Container

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

4A-2 FRONT DRIVE SHAFT
GENERAL DESCRIPTION
COMPONENT
A constant velocity ball joint is used on the wheel side of front drive shaft. For right side drive shaft of 2WD vehi-
cle, a constant velocity tripod joint on the differential side. For left side drive shaft of every type vehicles and
right side drive shaft of 4WD vehicle, a constant velocity double offset joint is used on the differential or transfer
side. The drive shaft can slide through the tripod joint or the double offset joint in the extension/contraction direc-
tion.
DIAGNOSIS
DIAGNOSIS TABLE
DRIVE SHAFT BOOT CHECK
Inspect drive shaft boot for tear.
If even a small tear is noted, replace with new one. Condition Possible Cause Correction
Abnormal Noise
Worn or breakage drive shaft joint Replace.
Worn or breakage center bearing Replace.

FRONT DRIVE SHAFT 4A-3
ON-VEHICLE SERVICE
1. Differential side joint (RH of 2WD M/T vehicle)
: Apply orange grease included in spare part to
joint.9. Differential (or transfer) side joint (LH of every type
vehicles)
: Apply black grease included in spare part to joint.17. Circlip
2. Boot (Differential, transfer or center shaft side) 10. Dynamic damper (RH of 2WD M/T vehicle) 18. Center shaft
3. Circlip 11. Dynamic damper (LH of 2WD A/T vehicle) 19. Center shaft side joint
(RH of 2WD A/T vehicle)
4. Boot band (Small) 12. Transfer side joint (RH of 4WD vehicle)
: Apply black grease included in spare part to joint.[A] : Constant velocity tripod
joint type
5. Snap ring 13. Oil seal
: Apply grease 99000-25010 to oil seal lip.[B] : Constant velocity double
offset joint type
6. Wheel side joint (Constant velocity joint)
: Apply black grease included in spare part to joint.14. Circlip [C] : Center shaft for 2WD A/T
vehicle
7. Boot (Wheel side) 15. Center bearing support Tightening torque
8. Boot band (Large) 16. Center bearing Do not reuse.

4A-4 FRONT DRIVE SHAFT
DRIVE SHAFT ASSEMBLY
REMOVAL
1) Undo caulking (“A”) and remove drive shaft nut (1) and
washer.
2) Hoist vehicle.
3) Remove wheel.
4) Drain transmission oil or transfer oil.
5) Remove tie rod end split pin (1) and castle nut (2).
6) Disconnect tie rod end (3) from steering knuckle (4) by using
special tool.
Special tool
(A) : 09913-65210
7) (For vehicle without center shaft or 4WD model)
Using tire lever (1), pull out drive shaft joint (2) so as to
release snap ring fitting of joint spline at differential side.
(For vehicle with center shaft or 4WD model)
Using plastic hammer, drive out drive shaft joint (2) so as to
release snap ring fitting of joint spline at center shaft or inter-
mediate shaft of transfer.
8) Remove two stabilizer mount brackets from vehicle body.
9) Disconnect front suspension control arm ball stud (1) from
steering knuckle (2) by pushing down stabilizer bar (4) after
removing ball stud bolt (3).
[A] : Vehicle without center shaft or 4WD model
[B] : Vehicle with center shaft or 4WD model

FRONT DRIVE SHAFT 4A-15
Tighten each bolt and nut to the specified torque.
Tightening torque
Transfer oil filler/level and drain plugs (a) :
21 N·m (2.1 kg-m, 15.5 lb-ft)
Transmission oil filler/level and drain plugs (b) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
Ball stud bolt (c) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Tie rod end castle nut (d) :
35 - 50 N·m (3.5 - 5.0 kg-m, 25.5 - 36.0 lb-ft)
Drive shaft nut (e) : 175 N·m (17.5 kg-m, 127.0 lb-ft)
Wheel nut (f) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Center bearing support bolts (g) :
50 N·m (5.0 kg-m, 36.0 lb-ft)
Apply sealant to drain plug (1) and filler/level plug (2) for
manual transmission.
“A” : Sealant 99000-31110
Apply sealant to drain plug (9) and filler/level plug (10) for
transfer. (For 4WD model)
“A” : Sealant 99000-31110
Fill transmission or transfer with oil as specified. (Refer to
Section 7A, 7B or 7D.)
[A] : For M/T vehicle
[B] : For A/T vehicle
[C] : For 4WD model
[D] : For vehicle equipped with center shaft
3. Drain plug (for A/T vehicle)
4. Ball stud bolt
5. Castle nut
6. Drive shaft nut
7. Wheel nut
8. Center bearing support bolt

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.

BRAKES 5-27
b) For 4WD vehicle :
Pull brake drum off by using 8 mm bolts.
INSPECTION
Brake Drum
Inspect brake drum for wear.
If limit value of drum inner diameter is exceeded or uneven or
stepped wear is excessive, replace drum.
Drum inner diameter “a”
Standard : 180 mm (7.09 in.)
Limit : 182 mm (7.17 in.)
Brake Shoe
Measure thickness of brake shoe (1) (not including backing
metal). Also, check surface of lining for hardening, excessive
wear and oil.
Brake shoe thickness
Standard : 3.9 mm (0.15 in.)
Limit : 1.0 mm (0.04 in.)
NOTE:
When drum is removed, visually inspect wheel cylinder
for brake fluid leakage. Correct leaky point, if any.
CAUTION:
Never polish lining with sandpaper. If lining is polished
with sandpaper, hard particles of sandpaper will be
deposited in lining and may damage drum. When it is
required to correct lining, replace it with a new one.