Disassembly and Assembly

Components

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 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 the pad, shim, shim cover, and pad retainer from the torque member.
2. Remove sliding pins and sliding pin boots from torque member.





3. 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.





4. Using a flat-bladed screwdriver, remove piston seal from cylinder body.

CAUTION: Be careful not to damage cylinder inner wall.

CALIPER INSPECTION
Cylinder Body

CAUTION:
^ Use new brake fluid for cleaning. 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
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above condition are observed.

CAUTION: Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials are stuck to sliding surface.

Sliding Pins, and Sliding Pin Boots
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present, replace the affected part.

ASSEMBLY

CAUTION: Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.





1. Apply rubber grease to new piston seal and insert seal 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. Install sliding pins and sliding pin boots to torque member.
5. Attach inner shim and inner shim cover to inner pad, and attach the outer shim to the outer pad.
6. Install cylinder body. Tighten sliding pin bolt to the specified torque.

DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them 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 the disc edge.)
Runout limit (with it attached to the vehicle): 0.04 mm (0.0016 inch)
Runout limit (Just the disc rotor): 0.02 mm (0.0008 inch)

NOTE: Make sure that wheel bearing axial end play is with in he specifications 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: 28.0 mm (1.102 inch)
Repair limit thickness: 26.0 mm (1.024 inch)
Maximum uneven wear (measured at 8 positions): 0.015 mm (0.0006 inch)