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Nissan FRONTIER 2008 User Manual

Nissan FRONTIER 2008
41 pages
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BR-1
BRAKES
C
D
E
G
H
I
J
K
L
M
SECTION BR
A
B
BR
N
O
P
CONTENTS
BRAKE SYSTEM
PRECAUTION ............................................... 3
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
3
Precaution for Brake System ....................................3
PREPARATION ............................................4
PREPARATION ................................................... 4
Special Service Tool .................................................4
Commercial Service Tool ..........................................4
FUNCTION DIAGNOSIS ............................... 5
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING .............................
5
NVH Troubleshooting Chart ......................................5
Hydraulic Circuit ........................................................6
BASIC INSPECTION .................................... 7
INSPECTION AND ADJUSTMENT ..................... 7
Brake Fluid Level Inspection .....................................7
Brake Booster Inspection ..........................................7
Pad Wear Inspection .................................................7
Brake Pedal Inspection and Adjustment ...................7
ON-VEHICLE MAINTENANCE ..................... 9
BRAKE FLUID ..................................................... 9
Drain and Refill ..........................................................9
Bleeding Brake System .............................................9
FRONT DISC BRAKE ........................................10
Component ..............................................................10
Removal and Installation of Brake Pad ...................11
Brake Burnishing .....................................................11
REAR DISC BRAKE ..........................................12
Component ..............................................................12
Removal and Installation of Brake Pad ...................13
Brake Burnishing .....................................................14
REMOVAL AND INSTALLATION ...............15
BRAKE PEDAL .................................................15
Removal and Installation .........................................15
BRAKE PIPING AND HOSE .............................18
Removal and Installation of Front Brake Piping
and Brake Hose .......................................................
18
Removal and Installation of Rear Brake Piping
and Brake Hose .......................................................
18
Inspection After Installation .....................................19
BRAKE MASTER CYLINDER ..........................20
Removal and Installation .........................................20
BRAKE BOOSTER ...........................................22
Removal and Installation .........................................22
VACUUM LINES ...............................................24
Removal and Installation .........................................24
FRONT DISC BRAKE .......................................25
Component ..............................................................25
Removal and Installation of Brake Caliper and
Disc Rotor ................................................................
26
Brake Burnishing .....................................................27
REAR DISC BRAKE .........................................28
Component ..............................................................28
Removal and Installation of Brake Caliper and
Disc Rotor ................................................................
29
Brake Burnishing .....................................................29
DISASSEMBLY AND ASSEMBLY ..............30
BRAKE MASTER CYLINDER ..........................30
Disassembly and Assembly .....................................30
FRONT DISC BRAKE .......................................32
Component ..............................................................32
Disassembly and Assembly of Brake Caliper ..........33
Revision: August 2007 2008 Frontier

Table of Contents

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Nissan FRONTIER 2008 Specifications

General IconGeneral
BrandNissan
ModelFRONTIER 2008
CategoryAutomobile
LanguageEnglish

Summary

PRECAUTIONS

SRS and Brake System Safety

Covers SRS and general brake system safety guidelines.

PREPARATION AND TOOLS

Service Tool Requirements

Lists special and commercial service tools for brake maintenance.

FUNCTION DIAGNOSIS

NVH Troubleshooting Guide

Guides diagnosing noise, vibration, and harshness in the brake system.

NVH TROUBLESHOOTING

Hydraulic Circuit Diagram

Diagram and notes on the brake hydraulic system layout.

BASIC INSPECTION AND ADJUSTMENT

Fluid Level and Booster Checks

Procedures for checking brake fluid level and inspecting the brake booster.

Pad Wear Inspection

Method to check brake pad thickness.

BRAKE PEDAL INSPECTION AND ADJUSTMENT

Pedal Height and Play Measurement

Procedures for measuring and adjusting brake pedal height and play.

ON-VEHICLE MAINTENANCE

Brake Fluid and Bleeding Procedures

Steps for draining, refilling, and bleeding the brake system.

FRONT DISC BRAKE COMPONENTS (Caliper)

Caliper and Pad Identification

Exploded view and parts list for the front disc brake caliper.

FRONT DISC BRAKE SERVICE (Pads)

Pad Replacement and Burnishing

Procedures for removing, installing, and burnishing front brake pads.

REAR DISC BRAKE COMPONENTS (Caliper)

Caliper and Pad Identification

Exploded view and parts list for the rear disc brake caliper.

REAR DISC BRAKE SERVICE (Pads)

Pad Replacement and Burnishing

Procedures for removing, installing, and burnishing rear brake pads.

REAR DISC BRAKE BURNISHING

Burnishing Procedure

Procedure for seating rear brake components after service.

BRAKE PEDAL REMOVAL AND INSTALLATION

Pedal Assembly Service

Steps to remove and install the brake pedal assembly.

BRAKE PEDAL VARIATIONS

Adjustable vs. Non-Adjustable Pedal Removal

Specific removal procedures for adjustable and non-adjustable pedals.

BRAKE PEDAL POST-SERVICE CHECKS

Inspection and Reassembly

Checks after removal and reassembly of the brake pedal.

BRAKE PIPING AND HOSE SERVICE

Front and Rear Line/Hose Replacement

Procedures for removing and installing front and rear brake piping and hoses.

BRAKE PIPING AND HOSE INSPECTION

Post-Installation Leak Checks

Checks for leaks and damage after installing brake lines and hoses.

BRAKE MASTER CYLINDER SERVICE

Cylinder Removal and Installation

Steps to remove and install the brake master cylinder.

BRAKE BOOSTER SERVICE

Booster Removal and Installation

Steps to remove and install the brake booster.

VACUUM LINES SERVICE

Brake Booster Hose Replacement

Procedures for removing and installing the brake booster vacuum hose.

FRONT DISC BRAKE COMPONENTS (Caliper)

Caliper and Pad Identification

Exploded view and parts list for the front disc brake caliper.

FRONT DISC BRAKE CALIPER SERVICE

Caliper and Rotor Replacement

Steps to remove and install the front brake caliper and disc rotor.

FRONT DISC BRAKE BURNISHING

Burnishing Procedure

Procedure for seating front brake components.

REAR DISC BRAKE COMPONENTS (Caliper)

Caliper and Pad Identification

Exploded view and parts list for the rear disc brake caliper.

REAR DISC BRAKE SERVICE (Caliper/Rotor)

Caliper and Rotor Replacement

Steps to remove and install the rear brake caliper and disc rotor.

Rear Disc Brake Burnishing

Procedure for seating rear brake components.

BRAKE MASTER CYLINDER DISASSEMBLY

Cylinder Disassembly and Assembly

Steps for disassembling and assembling the brake master cylinder.

FRONT DISC BRAKE CALIPER SERVICE (Disassembly)

Disassembly, Assembly, and Inspection

Steps to disassemble, assemble, and inspect the front brake caliper.

FRONT DISC BRAKE CALIPER ASSEMBLY

Caliper Reassembly and Rotor Inspection

Steps for assembling caliper and inspecting disc rotors.

FRONT DISC BRAKE ROTOR INSPECTION

Rotor Thickness Check

Checking disc rotor thickness for wear.

REAR DISC BRAKE COMPONENTS (Caliper)

Caliper and Pad Identification

Exploded view and parts list for the rear disc brake caliper.

REAR DISC BRAKE CALIPER SERVICE

Disassembly, Assembly, and Inspection

Steps to disassemble, assemble, and inspect the rear brake caliper.

REAR DISC BRAKE CALIPER ASSEMBLY

Caliper Reassembly and Rotor Inspection

Steps for assembling caliper and inspecting disc rotors.

REAR DISC BRAKE ROTOR INSPECTION

Rotor Thickness Check

Checking rear disc rotor thickness for wear.

SERVICE DATA AND SPECIFICATIONS (SDS) - GENERAL

General Component Specifications

General dimensional and specification data for brake components.

Brake Pedal Specifications

Specifications related to brake pedal height, play, and clearance.

SERVICE DATA AND SPECIFICATIONS (SDS) - SPECIFIC

Booster and Vacuum Line Specs

Specifications for brake booster, vacuum leakage, and check valve.

Disc Brake Component Specs

Specifications for front and rear disc brake pads and rotors.

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