Nissan Frontier. Manual - part 113

BR-32

< REMOVAL AND INSTALLATION >

VACUUM LINES

VACUUM LINES

Removal and Installation

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Brake Booster Vacuum Hose

REMOVAL

1. Disconnect brake booster hose from hose clip bracket.
2. Release the brake booster hose clamps 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 clamps.

CAUTION:

Do not use lubricating oil during installation.

WFIA0332E

1.

Brake booster hose

2.

Brake booster hose clamp

3.

Brake booster vacuum check valve

Vacuum hose length (A)

: 24 mm (0.94 in) or more

JPFIA0023ZZ

FRONT DISC BRAKE

BR-33

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FRONT DISC BRAKE

Exploded View of Brake Pads

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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, 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 rotors and pads 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-34, "Brake Burnishing"

.

Removal and Installation of Brake Pad

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REMOVAL

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

WT-48, "Adjustment"

.

2. Remove master cylinder reservoir cap.
3. Remove lower sliding pin bolt using power tool and swing the caliper body up to access the brake pads.
4. Support the caliper body with a suitable wire to avoid pulling on the front brake hose.
5. Remove the front inner and outer brake pads, shims, shim cover, pad return spring and retainers from the

torque member.

AWFIA1054ZZ

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

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Molykote 7439 grease

BR-34

< REMOVAL AND INSTALLATION >

FRONT DISC BRAKE

INSTALLATION

1. Apply Molykote 7439 grease (A) to the 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 the suitable wire, then swing caliper body down over pad assemblies.
6. Install the lower sliding pin bolt and tighten to specification. Refer to 

BR-35, "Exploded View of Brake Cal-

iper"

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7. Check the brakes for drag.
8. Inspect the brake fluid level, then install the master cylinder 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.

AWFIA0039ZZ

PFIA0273E

FRONT DISC BRAKE

BR-35

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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. 

• 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 rotors 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-34, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

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NOTE:

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

ing.

REMOVAL

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

WT-48, "Adjustment"

.

AWFIA0467GB

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