Disassembly and Assembly

CAUTION:
- Clean dust on the caliper and brake pad with a vacuum dust collector. Do not blow with compressed air.
- While removing cylinder body, never depress brake pedal because piston will pop out.
- It is not necessary to remove mounting bolts on the torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a wire so that brake hose is not under tension.
- Do not damage piston boot.
- Always replace shims and shim covers as a set when replacing brake pads.
- Keep rotor from brake fluid.

Caliper Disassembly and Assembly

DISASSEMBLY

1. Remove caliper assembly from vehicle.
2. Remove sliding pin bolts from cylinder body, and remove pad, shim, shim cover and pad retainer from torque member.
CAUTION:
When removing pad retainer from torque member, lift pad retainer in the direction shown by the arrow (shown in the figure) so as not to deform it.






3. Remove sliding pins and sliding pin boots from torque member.
4. Place a wooden block as shown at the right, and blow air from union bolt mounting hole to remove pistons and piston boots.






5. Remove piston seal with a flat-bladed screw driver.





INSPECTION AFTER DISASSEMBLY

Cylinder Body

CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
- Check the inner wall of cylinder for corrosion, wear, and damage. If a failure is detected, replace cylinder body.
- Minor flaws caused by corrosion or a foreign material can be removed by polishing the surface with a fine sandpaper. Replace cylinder body, if necessary.

Torque Member

Check for wear, cracks, and damage. If a malfunction is detected, replace applicable part.

Piston

CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check the piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.

Sliding Pin, Sliding Pin Bolt and Pin Boot

Check sliding pin, sliding pin bolt and sliding pin boot for wear, damage, and cracks. If a malfunction is detected, replace applicable part.

DISC ROTOR INSPECTION

Visual Inspection

Check the surface of disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected, replace applicable part.

Runout Inspection

1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check the runout.

Measurement point: At a point 10 mm (0.39 in) from the outer edge of disc.
Maximum runout: 0.035 mm (0.0014 in) or less

Make sure that wheel bearing axial end play is with in he specifications before measuring runout. Refer to, "On-Vehicle Inspection and Service" Front Wheel Bearing






3. If the runout is outside the limit, find the minimum runout point by shifting the mounting positions of disc rotor and wheel hub by one hole.
4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD DL-8700", "AMMCO 700 and 705" or equivalent).

Thickness Inspection

1. Using a micrometer, check the thickness of disc rotor. If the thickness is outside the standard, replace disc rotor.

Standard thickness :24.0 mm (0.945 in)
Wear limit :22.0 mm (0.866 in)
Maximum uneven wear (measured at 8 positions): 0.015 mm (0,0006 in) or less






2. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).

ASSEMBLY

CAUTION:
When assembling, do not use NISSAN rubber grease (KRE00 00010, KRE00 00010 01).

1. Apply rubber grease to new piston seals, and install them to groove on cylinder body.
CAUTION:
Do not reuse piston seal.






2. Apply rubber grease to piston boots. Cover piston end with piston boot, and install cylinder-side lip on the piston boot properly into the groove on the cylinder body.
CAUTION:
Do not reuse piston boot.






3. Apply brake fluid "DOT3" to piston, and press piston into cylinder body by hand to assemble piston-side lip on the piston boot properly into the groove on the piston.
CAUTION:
Press the piston evenly and change the pressing point to prevent the inner wall of cylinder from being rubbed.






4. Install sliding pins and sliding pin boots to torque member.
5. Install torque member to knuckle spindle and tighten torque member fixing bolts to the specified torque.
CAUTION:
Before installing the torque member to vehicle, wipe oil and grease on the washer seats on the knuckle spindle and mounting surface of torque member.
6. Install pad retainers to torque member.
7. After assembling shims and shim covers to pad, install it to torque member.
CAUTION:
Inner pad and outer pad have the pad-return mechanism on the upper side of pad retainer. When installing pad, be sure to install pad return lever to pad wear sensor securely shown to the right.






8. Install cylinder body, and tighten sliding pin bolt to the specified torque.
9. Install brake hose to cylinder body and tighten union bolt to the specified torque.
CAUTION:
- Assemble brake hose securely to the protrusions on the cylinder body.
- Do not reuse copper washer for union bolts.