Disassembly and Assembly
Components
WARNING: Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.
CAUTION:
^ While removing cylinder 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 assembly. In this case, hang cylinder body with a wire so as not to stretch brake hose.
^ Do not damage piston boot.
^ If any shim is subject to serious corrosion, replace it with a new one.
^ Always replace shims and shim covers as a set when replacing brake pads.
^ Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft pedal occurs at very low mileage.
Disassembly and Assembly of Brake Caliper Assembly
DISASSEMBLY
1. Remove sliding pin bolt, and then remove pad, shim, shim cover, and pad retainer from torque member and cylinder.
2. Remove sliding pin boot from torque member.
3. As shown in the figure, using a screwdriver, remove retaining ring from cylinder body.
4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION: Do not get your fingers caught in piston.
5. Using a flat-bladed screwdriver, remove piston seals from cylinder body.
CAUTION: Be careful not to damage cylinder inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:
^ Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
^ Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above conditions 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.
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:
^ Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials are stuck to sliding surface.
^ Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above condition are observed.
Sliding Pin Bolts and Sliding Pin Boots
Make sure there is no wear, damage, or cracks in sliding pin bolts and sliding pin boots, and if there are, replace them.
ASSEMBLY
CAUTION: Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
1. Apply a rubber grease to new piston seal and insert in to groove on cylinder body.
CAUTION: Do not reuse piston seal.
2. Apply brake fluid to piston rubber grease to piston boot, then install piston boot in to piston groove.
CAUTION: Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION: Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4. Fix piston boot with retaining ring.
CAUTION:
^ Make sure boot is firmly in cylinder body groove.
^ Do not reuse retaining ring.
5. Install sliding pin bolt and sliding pin boots to torque member.
6. Apply Poly Butyl Cuprysil (PBC) grease or silicon- based grease to the backside of pad and to both sides of shim, and attach inner shim and shim cover to inner pad, and the outer shim and outer shim cover to outer pad.
7. Assembling shims and shim covers to pad.
CAUTION: When attaching pad retainer, attach it firmly so that it does not float up higher than torque member, as shown in the figure.
8. Attach pad retainer and pad to torque member.
9. Install cylinder body. Tighten sliding pin bolts to the specified torque.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is detected, replace applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheel hub. (2 or more positions)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 inch) inside disk edge.]
Runout limit (with it attached to the vehicle): 0.05 mm (0.0020 inch)
NOTE: Make sure that wheel bearing axial end play is within the specification before measuring runout.
3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one hole.
4. If runout still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is outside the standard, replace disc rotor.
Standard thickness: 16.0 mm (0.630 inch)
Wear limit: 14.0 mm (0.551 inch)
Maximum uneven wear (measured at 8 positions): 0.015 mm (0.0006 inch)