Nissan Frontier. Manual - part 115

BR-40

< REMOVAL AND INSTALLATION >

REAR DISC BRAKE

Exploded View of Brake Caliper

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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, 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 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-39, "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 rear wheel and tire using power tool. Refer to 

WT-48, "Adjustment"

.

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1.

Union bolt

2.

Brake hose

3.

Copper sealing 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

REAR DISC BRAKE

BR-41

< REMOVAL AND INSTALLATION >

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2. Remove the union bolt (A) then disconnect the brake hose and

discard the copper sealing washers.

CAUTION:

Do not reuse copper sealing washers.

3. Remove the sliding pin bolts (A) and remove the caliper body

from torque member.

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

mark (A) 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 (A) 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-40, "Exploded

View of Brake Caliper"

.

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

BR-38, "Exploded View of

Brake Pad"

.

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< REMOVAL AND INSTALLATION >

REAR DISC BRAKE

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

bolts (A) to the specified torque. Refer to 

BR-40, "Exploded View

of Brake Caliper"

.

CAUTION:

When installing the caliper body to the torque member,

wipe any oil off of the 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-12,

"Hydraulic Circuit"

.

CAUTION:

Do not reuse copper sealing washers.

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

BR-18, "Bleeding Brake

System"

.

CAUTION:

• Refill with new brake fluid.

• Do not reuse drained brake fluid.

7. Install the rear wheel and tire. Refer to 

WT-48, "Adjustment"

.

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BRAKE MASTER CYLINDER

BR-43

< UNIT DISASSEMBLY AND ASSEMBLY >

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UNIT DISASSEMBLY AND ASSEMBLY

BRAKE MASTER CYLINDER

Disassembly and Assembly

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Brake Master Cylinder

DISASSEMBLY

CAUTION:

• Master cylinder sub-assembly cannot be disassembled.

• Remove reservoir tank only when absolutely necessary.

• While working, cover the primary piston rod with a cloth to prevent it from being damaged.

• Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.

• Do not drop parts. If a part is dropped, do not use it.

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1.

Reservoir cap

2.

Strainer

3.

Fluid level sensor

4.

Reservoir tank

5.

Grommet

6.

Restriction washer

7.

Master cylinder sub-assembly

8.

O-ring

9.

Brake booster

10. Pin

A.

PBC (Poly Butyl Cuprysil) grease 
or silicone based grease

B.

Brake fluid

C.

M/T models only

R.

Rubber grease

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