Nissan Frontier D40. Manual - part 70

BR-36

< ON-VEHICLE REPAIR >

BRAKE BOOSTER

2.

Remove the brake piping from the brake master cylinder.

3.

Remove the brake master cylinder. Refer to 

BR-33, "Removal and Installation"

.

4.

Remove brake booster vacuum hose from the brake booster. Refer to 

BR-38, "Removal and Installation"

.

5.

Remove instrument panel LH. Refer to 

IP-17, "Exploded View"

.

6.

Remove the brake pedal clevis pin (2) and snap pin (1) from
inside the vehicle. 

7.

Remove the brake booster and brake pedal assembly nuts and discard.

CAUTION:

Discard the nuts, do not reuse.

8.

Remove brake booster assembly from dash panel.

INSTALLATION

1.

Loosen the lock nut (1) to adjust the input rod (2) so that length
(A) is within the specified value.

2.

After adjusting input rod length (A), temporarily tighten the lock
nut (1) and install the booster assembly to the dash panel.
• Install gaskets and spacer block between the booster assem-

bly and the dash panel.

3.

Connect the input rod using the brake pedal clevis pin (2) and
snap pin (1) from inside the vehicle. 

4.

Install the brake booster using new nuts.

CAUTION:

Do not reuse the brake booster and brake pedal assembly nuts.

5.

Install the brake master cylinder. Refer to 

BR-33, "Removal and Installation"

.

6.

Install the brake piping to the brake master cylinder. Refer to 

BR-13, "Hydraulic Circuit"

.

7.

Connect the brake booster vacuum hose and check valve to the brake booster.

8.

Adjust the brake pedal height. Refer to 

BR-19, "Inspection and Adjustment"

.

9.

Install lower instrument panel LH. Refer to 

IP-17, "Exploded View"

.

10. Install dash side finisher. Refer to 

INT-22, "Removal and Installation"

.

11. Tighten the input rod lock nut to specification.

JPFIA0019ZZ

Input rod (2) with lock nut (1) 
length (A) standard dimension

: Refer to 

BR-58, "Brake 

Booster"

.

JPFIA0238ZZ

JPFIA0019ZZ

BRAKE BOOSTER

BR-37

< ON-VEHICLE REPAIR >

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12. Install the ABS actuator and electric unit (control unit). Refer to 

BRC-71, "Removal and Installation"

 (type

1), 

BRC-180, "Removal and Installation"

 (type2), 

BRC-300, "Removal and Installation"

 (type 3).

13. Refill with new brake fluid and bleed the air. Refer to 

BR-21, "Bleeding Brake System"

.

BR-38

< ON-VEHICLE REPAIR >

VACUUM LINES

VACUUM LINES

Removal and Installation

INFOID:0000000005272483

Brake Booster Vacuum Hose

REMOVAL

1.

Disconnect brake booster hose from hose clip bracket.

2.

Release the brake booster hose clips and remove the brake booster hose. 

3.

Remove the check valve from the brake booster.

INSTALLATION

Installation is in the reverse order of removal.
• Insert vacuum hose onto tube and brake booster vacuum check

valve for a minimum length (A) before installing the brake booster
hose clips.

CAUTION:

Do not use lubricating oil during installation.

WFIA0332E

1.

Brake booster hose

2.

Brake booster hose clip

3.

Brake booster vacuum check valve

Vacuum hose length (A)

: 24 mm (0.94 in) or more

JPFIA0023ZZ

FRONT DISC BRAKE

BR-39

< ON-VEHICLE REPAIR >

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FRONT DISC BRAKE

Exploded View of Brake Pads

INFOID:0000000005272484

Front Brake Pads, Shims and Retainers

WARNING:

Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.

CAUTION:

• While removing brake pads never depress brake pedal because piston will pop out. 
• It is not necessary to remove bolts on torque member and brake hose except for disassembly or

replacement of caliper body. In this case, hang caliper body with a wire so as not to stretch the brake
hose.

• Do not damage the piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim cover as a set when replacing brake pads.
• Keep rotor free from brake fluid.
• Burnish the brake contact surface after refinishing or replacing rotors, after replacing pads, or if a

soft pedal occurs at very low mileage. Refer to 

BR-40, "Brake Burnishing"

.

Removal and Installation of Brake Pad

INFOID:0000000005272485

REMOVAL

1.

Remove the front wheel and tire. Refer to 

WT-46, "Rotation"

.

2.

Remove master cylinder reservoir cap.

3.

Partially drain brake fluid.

4.

Remove caliper sliding pin bolts using power tool.

AWFIA0599ZZ

1.

Inner shim

2.

Pad return spring

3.

Upper pad retainer

4.

Lower pad retainer

5.

Inner brake pad

6.

Outer brake pad

7.

Outer shim

8.

Outer shim cover

M.

Molykote AS-880N grease

N.

Molykote 7439 grease