Nissan Xterra. Manual - part 73

BR-1

BRAKES

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SECTION 

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CONTENTS

BRAKE SYSTEM

PRECAUTION ...............................................

3

PRECAUTIONS ...................................................

3

Precaution for Supplemental Restraint System 
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................

3

Precaution for Brake System  ....................................

3

PREPARATION ............................................

4

PREPARATION ...................................................

4

Special Service Tool  .................................................

4

Commercial Service Tool  ..........................................

4

SYSTEM DESCRIPTION  ..............................

5

NOISE, VIBRATION AND HARSHNESS 
(NVH) TROUBLESHOOTING  .............................

5

NVH Troubleshooting Chart  ......................................

5

BASIC INSPECTION  ....................................

6

FRONT DISC BRAKE .........................................

6

BRAKE PAD ................................................................

6

BRAKE PAD : Inspection  ..........................................

6

DISC ROTOR ...............................................................

6

DISC ROTOR : Inspection  ........................................

6

REAR DISC BRAKE ...........................................

8

BRAKE PAD ................................................................

8

BRAKE PAD : Inspection  ..........................................

8

DISC ROTOR ...............................................................

8

DISC ROTOR : Inspection  ........................................

8

BRAKE BOOSTER  .............................................

9

Inspection ..................................................................

9

VACUUM LINES .................................................

10

Inspection ................................................................

10

BRAKE MASTER CYLINDER  ..........................

11

On Board Inspection ................................................

11

BRAKE TUBE AND HOSE  ...............................

12

Hydraulic Circuit  ......................................................

12

FRONT BRAKE  .........................................................

13

FRONT BRAKE : Inspection ....................................

13

REAR BRAKE ............................................................

14

REAR BRAKE : Inspection  ......................................

14

PERIODIC MAINTENANCE  ........................

15

BRAKE PEDAL .................................................

15

Inspection and Adjustment  ......................................

15

BRAKE FLUID  ..................................................

17

On Board Inspection ................................................

17

Drain and Refill  ........................................................

17

Bleeding Brake System  ...........................................

17

REMOVAL AND INSTALLATION ...............

19

BRAKE PEDAL .................................................

19

Exploded View .........................................................

19

Removal and Installation  .........................................

19

BRAKE TUBE AND HOSE  ...............................

21

Hydraulic Circuit  ......................................................

21

Removal and Installation of Front Brake Piping 
and Brake Hose .......................................................

22

Removal and Installation of Rear Brake Piping 
and Brake Hose .......................................................

23

Inspection After Installation  .....................................

24

BRAKE MASTER CYLINDER  ..........................

26

Removal and Installation  .........................................

26

BRAKE BOOSTER  ...........................................

28

Removal and Installation  .........................................

28

VACUUM LINES  ...............................................

31

BR-2

Removal and Installation  ........................................

31

FRONT DISC BRAKE ........................................

32

Exploded View of Brake Pads  ................................

32

Removal and Installation of Brake Pad  ..................

32

Brake Burnishing  ....................................................

33

Exploded View of Brake Caliper  .............................

34

Removal and Installation of Brake Caliper and 
Disc Rotor ...............................................................

34

REAR DISC BRAKE ..........................................

37

Exploded View of Brake Pad  ..................................

37

Removal and Installation of Brake Pad  ..................

37

Brake Burnishing  ....................................................

38

Exploded View of Brake Caliper  .............................

39

Removal and Installation of Brake Caliper and 
Disc Rotor ...............................................................

39

UNIT DISASSEMBLY AND ASSEMBLY ....

43

BRAKE MASTER CYLINDER  ...........................

43

Disassembly and Assembly ....................................

43

FRONT DISC BRAKE  .......................................

45

Exploded View of Brake Caliper  .............................

45

Disassembly and Assembly  ....................................

45

REAR DISC BRAKE ..........................................

48

Exploded View of Brake Caliper  .............................

48

Disassembly and Assembly  ....................................

48

SERVICE DATA AND SPECIFICATIONS 
(SDS) ..........................................................

51

SERVICE DATA AND SPECIFICATIONS 
(SDS) .................................................................

51

General Specification ..............................................

51

Brake Pedal  ............................................................

51

Brake Booster  .........................................................

52

Check Valve ............................................................

52

Front Disc Brake  .....................................................

52

Rear Disc Brake ......................................................

52

PRECAUTIONS

BR-3

< PRECAUTION >

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PRECAUTION

PRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT 
PRE-TENSIONER"

INFOID:0000000010203657

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along

with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain

types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS

system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front

air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the SR and SB section of this Service Man-

ual.

WARNING:

• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision which would result in air bag inflation, all maintenance must be performed by

an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal

injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag

Module, see the SR section.

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-

ness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-

tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a

hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing

serious injury.

• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the

battery and wait at least three minutes before performing any service.

Precaution for Brake System

INFOID:0000000009484632

• Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to 

MA-12, "Flu-

ids and Lubricants"

.

• Do not reuse drained brake fluid.

• Be careful not to splash brake fluid on painted areas.

• To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.

• Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

• Use flare nut wrench when removing and installing brake tube.

• Always check tightening torque when installing brake lines.

• Before working, turn ignition switch to OFF and disconnect con-

nectors for ABS actuator and electric unit (control unit) or battery

negative terminal.

• Burnish the brake contact surfaces after refinishing or replacing

drums or rotors, after replacing pads or linings, or if a soft pedal

occurs at very low mileage.

Refer to 

BR-33, "Brake Burnishing"

.

WARNING:

• Clean brake pads and shoes with a waste cloth, then wipe

with a dust collector.

SBR686C

BR-4

< PREPARATION >

PREPARATION

PREPARATION

PREPARATION

Special Service Tool

INFOID:0000000009484633

The actual shape of the tools may differ from those illustrated here.

Commercial Service Tool

INFOID:0000000009484634

Tool number
(TechMate No.)
Tool name

Description

—

(J-46532)
Brake height tool

Measuring brake pedal height

38-PFM92
( — )
ProCut™ PFM Series Lathe

Refinishing rotors

LFIA0227E

ALFIA0092ZZ

Tool name

Description

1. Flare nut crowfoot
2. Torque wrench

Removing and installing brake piping
a: 10 mm (0.39 in) / 12 mm (0.47 in)

Power tool

Loosening nuts, screws and bolts

S-NT360

PIIB1407E