Nissan Frontier D40. Manual - part 72

BR-44

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REAR DISC BRAKE

REAR DISC BRAKE

Exploded View of Brake Pad

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Rear 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 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 inner and outer shims 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-45, "Brake Burnishing"

.

Removal and Installation of Brake Pad

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REMOVAL

1.

Remove the rear wheel and tire. Refer to 

WT-46, "Rotation"

.

2.

Partially drain brake fluid.

3.

Remove caliper sliding pin bolts using power tool.

4.

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

5.

Remove the rear inner and outer brake pads, shims and retainers from the torque member.

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1.

Inner shim

2.

Upper pad retainer

3.

Inner brake pad

4.

Outer brake pad

5.

Lower pad retainer

6.

Outer shim

A.

Molykote 7439 grease

B.

Molykote AS-880N grease

REAR DISC BRAKE

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INSTALLATION

1.

Apply Molykote AS-880N grease between the brake pad back plates and shims, then attach the shims to
the brake pads.

2.

Apply Molykote 7439 grease (A) to the pad retainers as shown

3.

Attach pad retainer to torque member, then install brake pad and
shim assemblies.

CAUTION:

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

4.

Using a suitable tool push piston into caliper body.

CAUTION:

By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
NOTE:
Use a suitable tool to make it easier to push the piston into the caliper body.

5.

Install the caliper body.

6.

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

BR-46, "Exploded View of Brake Caliper"

.

7.

Check the brakes for drag.

8.

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

9.

Install the rear 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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BR-46

< ON-VEHICLE REPAIR >

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 never 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 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-45, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

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REMOVAL

1.

Remove the rear wheel and tire. Refer to 

WT-46, "Rotation"

.

2.

Drain the brake fluid. Refer to 

BR-21, "Drain and Refill"

.

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1.

Union bolt

2.

Brake hose

3.

Copper 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

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3.

Remove the union bolt (A) then disconnect the brake hose and
discard the copper washers.

CAUTION:

Discard the copper washers, do not reuse.

4.

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

5.

Remove the brake pads, shims 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 (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-46, "Exploded

View of Brake Caliper"

.

3.

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

BR-44, "Exploded View of

Brake Pad"

.

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