Nissan Frontier D40. Manual - part 74

BR-52

< DISASSEMBLY AND ASSEMBLY >

FRONT DISC BRAKE

1.

Remove the caliper body from the torque member. Refer to 

BR-41, "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-53

< 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-41, "Removal and Installation of Brake Caliper

and Disc Rotor"

.

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BR-54

< DISASSEMBLY AND ASSEMBLY >

REAR DISC BRAKE

REAR DISC BRAKE

Exploded View of Brake Caliper

INFOID:0000000005272497

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"

.

Disassembly and Assembly

INFOID:0000000005272498

DISASSEMBLY

1.

Remove the caliper body from the torque member. Refer to 

BR-46, "Removal and Installation of Brake

Caliper and Disc Rotor"

.

2.

Remove the sliding sleeves and boots from the torque member.

AWFIA0471GB

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

BR-55

< DISASSEMBLY AND ASSEMBLY >

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3.

Place a wooden block in the cylinder body and blow air into the
union bolt hole to remove the piston and piston boot as shown.

WARNING:

Do not get your fingers caught between the piston and
wooden block.

4.

Remove the piston boot from the piston.

CAUTION:

Do not reuse piston boot.

5.

Remove piston seal from cylinder body, using a suitable tool.

CAUTION:

Be careful not to damage cylinder body inner wall.

6.

Remove the bleed valve and cap.

CALIPER INSPECTION

Cylinder Body

• Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above condi-

tions are observed, replace 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 piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above
conditions 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 Pin Bolts 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.

ASSEMBLY

CAUTION:

Use NISSAN Rubber Grease when assembling.

1.

Install the bleed valve and cap.

BRD0041D

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