Disassembly and Assembly

Component







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 the 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 the rotor from brake fluid.

Caliper Disassembly and Assembly

DISASSEMBLY

1. Remove caliper assembly from vehicle.
2. Remove sliding pin bolts and cylinder body from torque member. Then remove pads, shims, and shim covers from torque member, and remove pad retainers from cylinder body.
3. Remove sliding pin boot from torque member.






4. Using a flat-bladed screwdriver as shown in the figure, remove retaining ring from torque member.
5. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove piston and piston boots.






6. Remove piston seal with a flat-bladed screw driver.
CAUTION:
Be careful not damage cylinder inner wall.






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 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 Bolt and Sliding Pin Boot

Check sliding pin bolts 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: 0.10 mm (0.0039 in) or less

CAUTION:
Before measuring, make sure that the axle endplay is 0.05 mm (0.002in) or less.






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

Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions): 0.015 mm (0.0006 in) or less






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 brake fluid to piston boots. Cover piston end with piston boot, and install cylinder-side lip on the piston boots properly into the groove on the cylinder body.
CAUTION:
Do not reuse piston boot.
3. 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 piston evenly and change the pressing point to prevent the inner wall of cylinder from being rubbed.






4. Fix piston boot with retaining ring.
CAUTION:
- Make sure that boot is securely engaged in the groove on cylinder body.
- Do not reuse retaining ring.






5. Install sliding pin bolts and sliding pin boots to torque member.
6. Install torque member to axle assembly, and tighten torque member fixing bolt to the specified torque.
CAUTION:
Before installing torque member to axle assembly, wipe oil and grease on the washer seats on the axle assembly and mounting surface of torque member.
7. Install pad retainers to torque member.
CAUTION:
When installing pad retainer, attach it firmly so that it does not flat up higher than torque member, as shown in the figure.





8. After assembling inner shims and inner shim covers to pads, assemble it to torque member.
9. Install cylinder body, and tighten sliding pin bolts to the specified torque.
10. Install brake hose to cylinder body and tighten union bolts to the specified torque.
CAUTION:
- Assemble brake hose securely to the protrusions on the cylinder body.
- Do not reuse copper washer on the union bolts.

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.

Standard value: (measured at 10 mm (0.39 in) inside disc edge)
Measurement position : At a point 10 mm (0.39 in) from outer edge of disc.
Runout limit (with it attached to vehicle): 0.10 mm (0.0039 in) or less

CAUTION:
Make sure that wheel bearing axial end play is within the specification before measuring runout. Refer to, "On-Vehicle Inspection and Service" Rear Wheel Bearing





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 the runout is still out of specification, turn rotor with on-car brake lathe ("MAD DL-870", "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 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions): 0.015 mm (0.0006 in) or less