Nissan Xterra. Manual - part 81

FRONT DISC BRAKE

BR-33

< REMOVAL AND INSTALLATION >

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6. Remove the front inner and outer brake pads, shims, shim cover, pad return spring and retainers from the

torque member.

INSTALLATION

1. Apply Molykote 7439 grease (A) to the upper and lower pad

retainers as shown.

2. Attach pad retainers to torque member. then install the brake

pads, shims and shim cover to the torque member.

CAUTION:

When attaching pad retainer, attach it firmly so that it is

flush with torque member, as shown.

3. Using a suitable tool push pistons into caliper body.

CAUTION:

When pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of

the brake fluid in the reservoir tank.

4. Install pad return spring to bottom edge of the brake pads in the holes provided.
5. Remove suitable wire, then swing caliper body down over brake pad assemblies.
6. Install the sliding pin bolts and tighten to specification. Refer to 

BR-34, "Exploded View of Brake Caliper"

.

7. Check the brakes for drag.
8. Inspect the brake fluid level, then install the reservoir cap.
9. Install the front wheel and tire. Refer to 

WT-48, "Adjustment"

.

Brake Burnishing

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Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after

replacing pads, or if a soft pedal occurs at very low mileage.

CAUTION:

Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust

brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.

3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

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BR-34

< REMOVAL AND INSTALLATION >

FRONT DISC BRAKE

Exploded View of Brake Caliper

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Front 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, do not 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 grease and 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-33, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

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REMOVAL

NOTE:

When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-

ing.

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1.

Sliding pin bolt

2.

Caliper body

3.

Piston seal

4.

Piston

5.

Piston boot

6.

Sliding pin

7.

Sliding pin boot

8.

Torque member bolt

9.

Torque member

10. Bleed valve

11. Cap

12. Copper sealing washers

13. Union bolt

14. Front brake hose

R.

Rubber grease

FRONT DISC BRAKE

BR-35

< REMOVAL AND INSTALLATION >

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1. Remove the front wheel and tire using power tool. Refer to 

WT-48, "Adjustment"

.

2. Remove reservoir cap.
3. Remove the union bolt then disconnect the brake hose and dis-

card the copper sealing washers.

CAUTION:

Do not reuse copper sealing washers.

4. Remove the sliding pin bolts and remove the caliper body from

the torque member.

5. Remove the brake pads, shims, shim cover and retainers from the torque member.
6. Remove the torque member bolts and remove the torque member.
7. Remove the disc rotor. If reusing the disc rotor, apply a matching

mark as shown for installation.

CAUTION:

Put matching marks on the wheel hub assembly and disc

rotor, if reusing the disc rotor.

INSTALLATION

1. Install the disc rotor. If reusing the disc rotor, align the matching

marks as shown for installation.

CAUTION:

Align the matching marks on the wheel hub assembly and

disc rotor, if reusing the disc rotor.

2. Install torque member and tighten the torque member bolts to specification. Refer to 

BR-34, "Exploded

View of Brake Caliper"

.

3. Install the brake pads, shims, shim cover and retainers on the torque member. Refer to 

BR-32, "Exploded

View of Brake Pads"

.

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BR-36

< REMOVAL AND INSTALLATION >

FRONT DISC BRAKE

4. Install caliper body and sliding pins, then tighten the sliding pin

bolts to the specified torque. Refer to 

BR-34, "Exploded View of

Brake Caliper"

.

CAUTION:

When installing the caliper body to the torque member,

wipe any oil off of the knuckle, washers and caliper body

attachment surfaces.

5. Install brake hose by aligning with the protrusion on caliper

body, then install new copper sealing washers (1) and union bolt

(A). Tighten union bolt (A) to specified torque. Refer to 

BR-34,

"Exploded View of Brake Caliper"

.

CAUTION:

Do not reuse copper sealing washers.

6. Refill with new brake fluid as necessary and bleed the brake system. Refer to 

BR-17, "Bleeding Brake

System"

.

CAUTION:

• Refill with new brake fluid. 

• Do not reuse drained brake fluid.

7. Install the reservoir cap.
8. Install the front wheel and tire. Refer to 

WT-48, "Adjustment"

.

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