Nissan Pathfinder (2009 year). Manual - part 96

BR-50

< DISASSEMBLY AND ASSEMBLY >

FRONT DISC BRAKE

1.

Remove the caliper body from the torque member. Refer to 

BR-39, "Removal and Installation of Brake

Caliper and Disc Rotor"

.

2.

Remove the upper sliding pin, lower sliding pin, and sliding pin boots from the torque member.

CAUTION:

Upper sliding pin must be replaced at each service.

3.

Place a wooden block as shown, and then blow air from the
union bolt hole to remove the pistons and piston boots.

WARNING:

Do not get your fingers caught between the pistons and
wooden block.

4.

Remove the piston boots from the pistons.

CAUTION:

Do not reuse piston boot.

5.

Remove piston seals from cylinder body, using a suitable tool.

CAUTION:

• Be careful not to damage cylinder body inner wall.
• Do not reuse piston seal.

6.

Remove the bleed valve and cap.

CALIPER INSPECTION

Cylinder Body

• Check the inside surface of the cylinder body for score, rust, wear, damage or foreign materials. If any of the

above conditions are observed, replace the cylinder body.

• Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper.

Replace cylinder body if necessary.

CAUTION:

• Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.

Torque Member

Check the torque member for wear, cracks, and damage. If damage or deformation is present, replace the
torque member.

Piston

Check the pistons for score, rust, wear, damage or presence of foreign materials. Replace if any of these con-
ditions are observed. 

CAUTION:

Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.

Sliding Pins, and Sliding Pin Boots

Check the sliding pins and sliding pin boots for wear, damage, and cracks. If damage or deformation is
present, replace the affected part.

CAUTION:

Upper sliding pin must be replaced at each service.

ASSEMBLY

BRB0032D

SFIA0141E

2009 Pathfinder

FRONT DISC BRAKE

BR-51

< DISASSEMBLY AND ASSEMBLY >

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CAUTION:

Use NISSAN Rubber Grease when assembling.
1.

Install the bleed valve and cap.

2.

Apply rubber grease to the new piston seals (1) and insert the
new piston seals (1) into the groove on the cylinder body.

CAUTION:

Do not reuse piston seals.

3.

Apply rubber grease to the new piston boots (1). Cover the pis-
ton end (2) with the piston boot (1), and then install the cylinder
side lip on the piston boot (1) securely into the groove on the cyl-
inder body.

CAUTION:

• Do not reuse piston boot.
• Press pistons in evenly and vary the pressing points to

prevent the cylinder inner wall from being damaged.

4.

Install the pistons (1) into the cylinder body and insert the piston
boots (2) side lip into the piston groove as shown. 

CAUTION:

Press pistons in evenly and vary the pressing points to pre-
vent the cylinder inner wall from being damaged.

5.

Apply rubber grease to the sliding pin boots, then install the new upper sliding pin, lower sliding pin, and
sliding pin boots on the torque member.

CAUTION:

Upper sliding pin must be replaced at each service.

6.

Install the cylinder body on the torque member. Refer to 

BR-39, "Removal and Installation of Brake Cali-

per and Disc Rotor"

.

JPFIA0032ZZ

JPFIA0033ZZ

JPFIA0034ZZ

2009 Pathfinder

BR-52

< DISASSEMBLY AND ASSEMBLY >

REAR DISC BRAKE

REAR DISC BRAKE

Exploded View of Brake Caliper

INFOID:0000000004414835

Rear Disc Brake Caliper

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 caliper body 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-43, "Brake Burnishing"

.

Disassembly and Assembly

INFOID:0000000003937522

DISASSEMBLY

1.

Remove the cylinder body. Refer to 

BR-44, "Removal and Installation of Brake Caliper and Disc Rotor"

.

2.

Remove the sliding sleeves and boots from the torque member.

AWFIA0471GB

1.

Union bolt

2.

Brake hose

3.

Copper washers

4.

Sliding pin bolt

5.

Cap

6.

Bleed valve

7.

Caliper body

8.

Sliding pin

9.

Piston seal

10. Piston

11. Piston boot

12. Torque member

13. Torque member bolt

14. Sliding pin boot

R.

Rubber grease

2009 Pathfinder

REAR DISC BRAKE

BR-53

< DISASSEMBLY AND ASSEMBLY >

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3.

Place a wooden block in the cylinder body and blow air into the
union bolt hole to remove the piston and piston boot as shown.

WARNING:

Do not get your fingers caught between the piston and
wooden block.

4.

Remove the piston boot from the piston.

CAUTION:

Do not reuse piston boot.

5.

Remove piston seal from cylinder body, using a suitable tool.

CAUTION:

Be careful not to damage cylinder body inner wall.

6.

Remove the bleed valve and cap.

CALIPER INSPECTION

Cylinder Body

• Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above condi-

tions are observed, replace cylinder body.

• Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper.

Replace cylinder body if necessary.

CAUTION:

• Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene. 

Torque Member

Check the torque member for wear, cracks, and damage. If damage or deformation is present, replace the
torque member.

Piston

Check the piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above
conditions are observed. 

CAUTION:

Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.

Sliding Pin Bolts and Sliding Pin Boots

Check the sliding pins and sliding pin boots for wear, damage, and cracks. If damage or deformation is
present, replace the affected part.

ASSEMBLY

CAUTION:

Use NISSAN Rubber Grease when assembling.

1.

Install the bleed valve and cap.

BRD0041D

JPFIA0038ZZ

2009 Pathfinder

BR-54

< DISASSEMBLY AND ASSEMBLY >

REAR DISC BRAKE

2.

Apply rubber grease to the new piston seal (1) and insert the
new piston seal (1) into the groove on the cylinder body.

CAUTION:

Do not reuse piston seal.

3.

Apply rubber grease to the new piston boot (1). Cover the piston
end (2) with the piston boot (1), and then install the cylinder side
lip on the piston boot (1) securely into the groove on the cylinder
body.

CAUTION:

• Do not reuse piston boot.
• Press pistons in evenly and vary the pressing points to

prevent the cylinder inner wall from being damaged.

4.

Install the piston (1) into the cylinder body and insert the piston
boot (2) side lip into the piston groove as shown. 

CAUTION:

Press pistons in evenly and vary the pressing points to pre-
vent the cylinder inner wall from being damaged.

5.

Apply rubber grease to the sliding pin boots, then install the sliding pins and sliding pin boots on the torque
member.

6.

Install the cylinder body on the torque member. Refer to 

BR-44, "Removal and Installation of Brake Cali-

per and Disc Rotor"

.

JPFIA0039ZZ

JPFIA0040ZZ

JPFIA0041ZZ

2009 Pathfinder

SERVICE DATA AND SPECIFICATIONS (SDS)

BR-55

< SERVICE DATA AND SPECIFICATIONS (SDS) 

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specification

INFOID:0000000003937523

Unit: mm (in)

Brake Pedal

INFOID:0000000003937524

ADJUSTABLE PEDAL

Unit: mm (in)

CAUTION:

When equipped with adjustable pedal, the pedal must be in the forward most position (closest to the floor) for pedal height
adjustment.

Front brake

Brake model

CLZ33VA

Rotor outer diameter 

×

 thickness

296 

×

 28 (11.654 

×

 1.102)

Pad Length 

×

 width 

×

 thickness

130 

×

 53.5 

×

 10.0 (5.118 

×

 2.106 

×

 0.394)

Cylinder bore diameter (each)

46.4 (1.827)

Rear brake 

Brake model

CLZ14VB

Rotor outer diameter 

×

 thickness

308 

×

 18 (12.126 

×

 0.709)

Pad Length 

×

 width 

×

 thickness

87.6 

×

 37.0 

×

 11.0 (3.449 

×

 1.457 

×

 0.433)

Cylinder bore diameter

38.1 (1.500)

Control valve

Valve model

Electric brake force distribution

Brake booster

Booster model

C215T

Diaphragm diameter

215 (8.465)

Recommended brake fluid

Refer to 

MA-12, "Fluids and Lubricants"

.

Pedal free height (H) with pedal in forward most position

182.1 (7.17)

Pedal travel (T)
[Depressed under a force of 490 N (50 kg, 110 lb) with engine running]

153 (6.02)

Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch

0.74 - 1.96 (0.029 - 0.077)

ALFIA0149ZZ

2009 Pathfinder

BR-56

< SERVICE DATA AND SPECIFICATIONS (SDS) 

SERVICE DATA AND SPECIFICATIONS (SDS)

STANDARD PEDAL

Unit: mm (in)

Brake Booster

INFOID:0000000003937525

Unit: mm (in)

Check Valve

INFOID:0000000003937526

Pedal free height (H)

182.1 (7.17)

Pedal full stroke (S)
[Depressed under a force of 490 N (50 kg, 110 lb) with engine running]

153 (6.02)

Clearance between pedal stopper and threaded end of stop lamp switch and ASCD 
switch (C

1

) or (C

2

)

0.74 - 1.96 (0.029 - 0.077)

AWFIA0433ZZ

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

149 

±

 0.5 (5.87 

±

 0.02)

JPFIA0238ZZ

Vacuum leakage 
[at vacuum of -66.7 kPa(-500 mmHg, -19.69 inHg)]

Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds

2009 Pathfinder

SERVICE DATA AND SPECIFICATIONS (SDS)

BR-57

< SERVICE DATA AND SPECIFICATIONS (SDS) 

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Front Disc Brake

INFOID:0000000003937527

Unit: mm (in)

Rear Disc Brake

INFOID:0000000003937528

Unit: mm (in)

Brake model

CLZ33VB

Brake pad

Standard thickness (new)

10.0 (0.394)

Repair limit thickness

2.0 (0.079)

Disc rotor

Standard thickness (new)

28.0 (1.102)

Repair limit thickness

26.0 (1.024)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006) 

Runout limit (with it attached to the vehicle)

0.05 (0.0020) 

Brake model

CLZ14VB

Brake pad

Standard thickness (new)

11.0 (0.433)

Repair limit thickness

2.0 (0.079)

Disc rotor

Standard thickness (new)

18.0 (0.709)

Repair limit thickness

16.0 (0.630)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006) 

Runout limit (with it attached to the vehicle)

0.05 (0.0020) 

2009 Pathfinder