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