Nissan Pathfinder (2008 year). Manual - part 85

FRONT DISC BRAKE

BR-27

< REMOVAL AND INSTALLATION >

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Brake Burnishing

INFOID:0000000001297450

Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.

CAUTION:

Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1.

Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).

2.

Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.

3.

To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.

4.

Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

BR-28

< REMOVAL AND INSTALLATION >

REAR DISC BRAKE

REAR DISC BRAKE

Component

INFOID:0000000001297452

Rear Disc Brake Caliper and Pads

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 cylinder body. In this case, hang cylinder body with a wire so as not to stretch brake
hose.

AWFIA0038GB

1.

Union bolt

2.

Brake hose

3.

Copper washers

4.

Sliding pin bolt

5.

Cap

6.

Bleed valve

7.

Cylinder body

8.

Sliding pin

9.

Piston seal

10. Piston

11. Piston boot

12. Torque member

13. Torque member bolt

14. Pad retainer

15. Outer shim

16. Outer brake pad

17. Inner brake pad

18. Inner shim

A.

Molykote 7439 refer to 

BR-13

   for 

application areas

B.

Brake fluid

C.

Molykote 77

R.

Rubber grease

: Front

REAR DISC BRAKE

BR-29

< REMOVAL AND INSTALLATION >

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• Do not damage piston boot.
• Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft

pedal occurs at very low mileage. Refer to 

BR-14, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

INFOID:0000000001297454

REMOVAL

1.

Remove wheel and tire using power tool.

2.

Drain brake fluid. Refer to 

BR-9, "Drain and Refill"

.

3.

Remove union bolt and bolts, and remove cylinder body.

4.

Remove torque member.

5.

Remove disc rotor.

INSTALLATION

CAUTION:

• Refill with new brake fluid. Refer to 

BR-9, "Drain and Refill"

.

• Do not reuse drained brake fluid.

1.

Install disc rotor.

2.

Install torque member and tighten to specification. Refer to 

BR-12, "Component"

.

3.

Install cylinder body to the vehicle, and tighten mounting bolts to specification.

CAUTION:

Before installing cylinder body to the vehicle, wipe off mounting surface of cylinder body.

4.

Install brake hose to cylinder body and tighten union bolt to specification. Refer to 

BR-12, "Component"

.

CAUTION:

• Do not reuse copper washer for union bolt.
• Securely attach brake hose to protrusion on cylinder body.

5.

Refill new brake fluid and bleed air. Refer to 

BR-9, "Bleeding Brake System"

.

6.

Install tires to the vehicle.

Brake Burnishing

INFOID:0000000001297456

Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.

CAUTION:

Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1.

Drive the vehicle on a straight smooth road at 50 km/h (31 MPH). 

2.

Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.   

3.

To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.

4.

Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

LFIA0211E

BR-30

< DISASSEMBLY AND ASSEMBLY >

BRAKE MASTER CYLINDER

DISASSEMBLY AND ASSEMBLY

BRAKE MASTER CYLINDER

Disassembly and Assembly

INFOID:0000000001297486

Components

DISASSEMBLY

CAUTION:

• Master cylinder cannot be disassembled.
• Remove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.

ASSEMBLY

CAUTION:

• Never use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
• Do not drop parts. If a part is dropped, do not use it.

WFIA0411E

1.

Reservoir cap

2.

Strainer

3.

Fluid level sensor

4.

Reservoir tank

5.

Grommet

6.

Restriction washer

7.

Master cylinder sub-assembly

8.

Fluid pressure sensor

9.

O-ring

10. Brake booster

⇐

Front

B.

Brake fluid

R.

Rubber grease

BRAKE MASTER CYLINDER

BR-31

< DISASSEMBLY AND ASSEMBLY >

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1.

Apply brake fluid or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer
to 

GI-26, "Recommended Chemical Products and Sealants"

.

CAUTION:

Do not reuse grommet.

2.

Install reservoir tank onto master cylinder assembly.

BR-32

< DISASSEMBLY AND ASSEMBLY >

FRONT DISC BRAKE

FRONT DISC BRAKE

Component

INFOID:0000000001297661

Front Disc Brake Caliper and Pads

WARNING:

Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.

CAUTION:

AWFIA0077GB

1.

Sliding pin bolt

2.

Cylinder body

3.

Piston seal

4.

Piston

5.

Piston boot

6.

Sliding pin

7.

Sliding pin boot

8.

Torque member bolt

9.

Torque member

10.

Upper pad retainer

11.

Outer shim

12. Inner brake pad

13.

Outer brake pad

14. Lower pad retainer

15. Shim cover

16.

Bleed valve

17. Cap

18. Copper washers

19.

Union bolt

20. Brake hose

21. Pad return spring

B.

Brake fluid

R.

Rubber grease

⇐

: Front

FRONT DISC BRAKE

BR-33

< DISASSEMBLY AND ASSEMBLY >

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• 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 cylinder body. In this case, hang cylinder body with a wire so as not to stretch brake
hose.

• Do not damage piston boot.
• Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft

pedal occurs at very low mileage. Refer to 

BR-11, "Brake Burnishing"

.

Disassembly and Assembly of Brake Caliper

INFOID:0000000001297487

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, and blow air from union bolt
mounting hole to remove pistons and piston boots.

CAUTION:

Do not get your fingers caught in piston.

4.

Remove piston seal from cylinder body, using a suitable tool.

CAUTION:

• Be careful not to damage cylinder inner wall.
• Do not reuse piston seal.

CALIPER INSPECTION

Cylinder Body

CAUTION:

• Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene. Refer to 

MA-

10, "Fluids and Lubricants"

.

• 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 con-
ditions are observed. 

CAUTION:

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

Sliding Pins, and Sliding Pin Boots

BRB0032D

SFIA0141E

BR-34

< DISASSEMBLY AND ASSEMBLY >

FRONT DISC BRAKE

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

CAUTION:

Trailing/upper sliding pin must be replaced at each service.

ASSEMBLY

CAUTION:

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

1.

Apply clean brake fluid to new piston seal and insert seal into
groove on cylinder body.

CAUTION:

Do not reuse piston seal.

2.

Apply clean brake fluid to piston boot. Cover the piston end with
piston boot, and then install cylinder side lip on piston boot
securely into a groove on cylinder body.

CAUTION:

Do not reuse piston boot.

3.

Apply brake fluid to piston, then install piston into cylinder body
and insert piston boot side lip into groove of piston as shown. 

CAUTION:

Press the piston evenly to prevent damage to cylinder wall.

4.

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.

5.

Install sliding pins and sliding pin boots to torque member.

CAUTION:

Trailing/upper sliding pin must be replaced at each service.

6.

Install cylinder body. Tighten sliding pin bolt to the specified torque. Refer to 

BR-25, "Component"

.

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.

Fix disc rotor to wheel hub in two or more positions, using wheel nuts.

SFIA2399E

SFIA2432E

WFIA0211E