Nissan Frontier. Manual - part 116

BR-44

< UNIT DISASSEMBLY AND ASSEMBLY >

BRAKE MASTER CYLINDER

1. Secure the flange of the master cylinder sub-assembly in a vise.

CAUTION:

• Use copper plates or a cloth to cover the flange before

securing it in the vise.

• When securing the master cylinder sub-assembly in a

vise, be sure not to over-tighten the vise.

2. Remove the pin and pull the reservoir tank off of the master cylinder sub-assembly.
3. Remove the grommets from the master cylinder sub-assembly body.

CAUTION:

Do not reuse grommets.

4. Remove the restriction washer from the master cylinder sub-assembly body.

CAUTION:

Do not reuse restriction washer.

5. Remove the fluid level sensor.

ASSEMBLY

Assembly is in the reverse order of 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.

• Do not reuse O-rings.

BRA0558D

FRONT DISC BRAKE

BR-45

< UNIT DISASSEMBLY AND ASSEMBLY >

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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 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"

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Disassembly and Assembly

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DISASSEMBLY

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

BR-46

< UNIT DISASSEMBLY AND ASSEMBLY >

FRONT DISC BRAKE

1. Remove the caliper body from the torque member. Refer to 

BR-35, "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

FRONT DISC BRAKE

BR-47

< UNIT 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 caliper body on the torque member. Refer to 

BR-35, "Removal and Installation of Brake Caliper

and Disc Rotor"

.

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