Nissan Frontier D40. Manual - part 71

BR-40

< ON-VEHICLE REPAIR >

FRONT DISC BRAKE

5.

Support the caliper body with a suitable wire to avoid pulling on the front brake hose.

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 AS-880N grease between outer brake pad backing and shims, then attach shim and shim
cover to brake pads.

2.

Apply Molykote 7439 grease as shown.

3.

Attach pad retainer to torque member. then install the brake pad,
shims and shim covers to the torque member.

CAUTION:

When attaching pad retainer, attach it firmly so that it is
flush with torque member, as shown.

4.

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.
NOTE:
Use a suitable tool to make it easier to push the pistons into the caliper body.

5.

Install pad return spring to bottom edge of the brake pads in the holes provided.

6.

Install the caliper body.

7.

Install the sliding pin bolts and tighten to specification. Refer to 

BR-41, "Exploded View of Brake Caliper"

.

8.

Check the brakes for drag.

9.

Inspect the brake fluid level, then install the master cylinder reservoir cap.

10. Install the front wheel and tire. Refer to 

WT-46, "Rotation"

.

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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FRONT DISC BRAKE

BR-41

< ON-VEHICLE REPAIR >

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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 never 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 rotor free from 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-40, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

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REMOVAL

1.

Remove the front wheel and tire. Refer to 

WT-46, "Rotation"

.

2.

Drain the brake fluid. Refer to 

BR-21, "Drain and Refill"

.

CAUTION:

• Refill with new brake fluid. 
• Do not reuse drained brake fluid.

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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 washers

13.

Union bolt

14. Front brake hose

R.

Rubber grease

BR-42

< ON-VEHICLE REPAIR >

FRONT DISC BRAKE

3.

Remove the union bolt then disconnect the brake hose and dis-
card the copper washers.

CAUTION:

Discard the copper washers, do not reuse.

4.

Remove the sliding pin bolts and remove the caliper body from
the torque member.

5.

Remove the brake pads, shims, shim covers 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-41, "Exploded

View of Brake Caliper"

.

3.

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

BR-39,

"Exploded View of Brake Pads"

.

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FRONT DISC BRAKE

BR-43

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4.

Install caliper body and sliding pins, then tighten the sliding pin
bolts to the specified torque. Refer to 

BR-41, "Exploded View of

Brake Caliper"

.

CAUTION:

When installing the caliper body to the torque member,
wipe any oil off of the knuckle spindle, washers and caliper
body attachment surfaces.

5.

Install brake hose by aligning with the protrusion on caliper
body, then install new copper washers and union bolt. Tighten
union bolt to specified torque. Refer to 

BR-41, "Exploded View

of Brake Caliper"

.

CAUTION:

Use new copper washers for installation.

6.

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

BR-21, "Bleeding Brake System"

.

CAUTION:

• Refill with new brake fluid. 
• Do not reuse drained brake fluid.

7.

Install the front wheel and tire. Refer to 

WT-46, "Rotation"

.

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