Nissan Pathfinder (2009 year). Manual - part 94

BR-34

< ON-VEHICLE REPAIR >

BRAKE BOOSTER

BRAKE BOOSTER

Removal and Installation

INFOID:0000000003937510

Brake Booster and Vacuum Hose

REMOVAL 

CAUTION:

• Be careful not to deform or bend brake piping while removing and installing brake booster.
• Replace clevis pin if it is damaged.
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined during

installation, dash panel may damage the threads.

• Attach the check valve in the correct direction.

1.

Remove the ABS actuator and electric unit (control unit). Refer to 

BRC-131, "Removal and Installation"

.

2.

Remove the brake piping from the brake master cylinder.

AWFIA0463GB

1.

Brake booster vacuum hose

2.

Brake booster vacuum check valve 3.

Brake booster

4.

Lock nut

5.

Gasket

6.

Spacer block

Front

2009 Pathfinder

BRAKE BOOSTER

BR-35

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3.

Remove the brake master cylinder. Refer to 

BR-32, "Removal and Installation"

.

4.

Remove brake booster vacuum hose from the brake booster. Refer to 

BR-34, "Removal and Installation"

.

5.

Remove the brake pedal clevis pin (2) and snap pin (1) from
inside the vehicle. 

6.

Remove the brake booster and brake pedal assembly nuts and discard.

CAUTION:

Discard the nuts, do not reuse.

7.

Remove brake booster assembly from dash panel.

INSTALLATION

1.

Loosen the lock nut (1) to adjust the input rod (2) so that length
(A) is within the specified value.

2.

After adjusting input rod length (A), temporarily tighten the lock
nut (1) and install the booster assembly to the dash panel.
• Install a gaskets and spacer block between the booster

assembly and the dash panel.

3.

Connect the input rod using the brake pedal clevis pin (2) and
snap pin (1) from inside the vehicle. 

4.

Install the brake booster using new nuts.

CAUTION:

Do not reuse the brake booster and brake pedal assembly nuts.

5.

Install the brake piping to the brake master cylinder. Refer to 

BR-26, "Hydraulic Circuit"

.

6.

Connect the brake booster vacuum hose and check valve to the brake booster.

7.

Install the brake master cylinder. Refer to 

BR-32, "Removal and Installation"

.

8.

Adjust the brake pedal height. Refer to 

BR-17, "Inspection and Adjustment - Standard Pedal"

, 

BR-18,

"Inspection and Adjustment - Adjustable Pedal"

.

9.

Tighten the input rod lock nut to specification.

10. Refill with new brake fluid and bleed the air. Refer to 

BR-20, "Drain and Refill"

.

JPFIA0019ZZ

Input rod (2) with lock nut (1) 
length (A) standard dimension

: Refer to 

BR-56, "Brake 

Booster"

.

JPFIA0238ZZ

JPFIA0019ZZ

2009 Pathfinder

BR-36

< ON-VEHICLE REPAIR >

VACUUM LINES

VACUUM LINES

Removal and Installation

INFOID:0000000003937511

Brake Booster Vacuum Hose

REMOVAL

1.

Disconnect brake booster hose from hose clip bracket.

2.

Release the brake booster hose clips and remove the brake booster hose. 

3.

Remove the check valve from the brake booster.

INSTALLATION

Installation is in the reverse order of removal.
• Insert vacuum hose onto tube and brake booster vacuum check

valve for a minimum length (A) before installing the brake booster
hose clips.

CAUTION:

Do not use lubricating oil during installation.

WFIA0332E

1.

Brake booster hose

2.

Brake booster hose clip

3.

Brake booster vacuum check valve

Vacuum hose length (A)

: 24 mm (0.94 in) or more

JPFIA0023ZZ

2009 Pathfinder

FRONT DISC BRAKE

BR-37

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FRONT DISC BRAKE

Exploded View of Brake Pads

INFOID:0000000004391549

Front Brake Pads, Shims and Retainers

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

• Do not damage the piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim cover as a set when replacing brake pads.
• Keep rotor free from brake fluid.
• Burnish the brake contact surface after refinishing or replacing rotors, after replacing pads, or if a

soft pedal occurs at very low mileage. Refer to 

BR-38, "Brake Burnishing"

.

Removal and Installation of Brake Pad

INFOID:0000000004391548

REMOVAL

1.

Remove the front wheel and tire. Refer to 

WT-48, "Rotation"

.

2.

Remove master cylinder reservoir cap.

3.

Remove lower sliding pin bolt using power tool and swing the caliper body up to access the brake pads.

4.

Support the caliper body with a suitable wire to avoid pulling on the front brake hose.

5.

Remove the front inner and outer brake pads, shims, shim covers and retainers from the torque member.

AWFIA0465ZZ

1.

Inner shim cover

2.

Inner shim

3.

Upper pad retainer

4.

Lower pad retainer

5.

Inner brake pad

6.

Outer brake pad

7.

Outer shim

8.

Cap

A.

Molykote M-77 grease

2009 Pathfinder

BR-38

< ON-VEHICLE REPAIR >

FRONT DISC BRAKE

INSTALLATION

1.

Apply Molykote M-77 grease between the inner and outer brake pad backing and shim, then attach shim
and shim covers to the brake pads.

2.

Attach pad retainer to torque member, then install the brake pad,
shims and shim covers to the torque member.

CAUTION:

When attaching pad retainer, attach it firmly so that it is
flush with torque member, as shown.

3.

Using a suitable tool push pistons into caliper body.

CAUTION:

When pushing in piston, brake fluid returns to master cylin-
der reservoir tank. Watch the level of the brake fluid in the
reservoir tank.
NOTE:
Use a suitable tool to make it easier to push the pistons into the
caliper body.

4.

Remove the suitable wire, then swing the caliper body down over the brake pad assemblies.

5.

Install the lower sliding pin bolt and tighten to specification. Refer to 

BR-37, "Exploded View of Brake

Pads"

.

6.

Check the brakes for drag.

7.

Inspect the brake fluid level, then install the master cylinder reservoir cap.

8.

Install the front wheel and tire. Refer to 

WT-48, "Rotation"

.

Brake Burnishing

INFOID:0000000003937514

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.

PFIA0273E

2009 Pathfinder

FRONT DISC BRAKE

BR-39

< ON-VEHICLE REPAIR >

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Exploded View of Brake Caliper

INFOID:0000000003937512

Front Disc Brake Caliper

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

• Do not damage the piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim cover as a set when replacing brake pads.
• Keep rotor free from brake fluid.
• Burnish the brake contact surface after refinishing or replacing rotors, after replacing pads, or if a

soft pedal occurs at very low mileage. Refer to 

BR-38, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

INFOID:0000000003937513

REMOVAL

1.

Remove the front wheel and tire. Refer to 

WT-48, "Rotation"

.

2.

Drain the brake fluid. Refer to 

BR-20, "Drain and Refill"

.

AWFIA0467GB

1.

Sliding pin bolt

2.

Caliper body

3.

Piston seal

4.

Piston

5.

Piston boot

6.

Sliding pin

7.

Sliding pin boot

8.

Torque member bolt

9.

Torque member

10.

Bleed valve

11.

Cap

12. Copper washers

13.

Union bolt

14. Front brake hose

R.

Rubber grease

2009 Pathfinder

BR-40

< ON-VEHICLE REPAIR >

FRONT DISC BRAKE

CAUTION:

• Refill with new brake fluid. 
• Do not reuse drained brake fluid.

3.

Remove the union bolt then disconnect the brake hose and dis-
card the copper washers.

CAUTION:

Discard the copper washers, do not reuse.

4.

Remove the sliding pin bolts and remove the caliper body from
the torque member.

5.

Remove the brake pads, shims, shim covers and retainers from the torque member.

6.

Remove the torque member bolts and remove the torque member.

7.

Remove the disc rotor. If reusing the disc rotor, apply a matching
mark as shown for installation.

CAUTION:

Put matching marks on the wheel hub assembly and disc
rotor, if reusing the disc rotor.

INSTALLATION

1.

Install the disc rotor. If reusing the disc rotor, align the matching
marks as shown for installation.

CAUTION:

Align the matching marks on the wheel hub assembly and
disc rotor, if reusing the disc rotor.

2.

Install torque member and tighten the torque member bolts to specification. Refer to 

BR-39, "Exploded

View of Brake Caliper"

.

3.

Install the brake pads, shims, shim covers and retainers on the torque member. Refer to 

BR-37,

"Exploded View of Brake Pads"

.

LFIA0235E

LFIA0239E

SDIA2608E

SDIA2608E

2009 Pathfinder

FRONT DISC BRAKE

BR-41

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4.

Install caliper body and sliding pins, then tighten the sliding pin
bolts to the specified torque. Refer to 

BR-39, "Exploded View of

Brake Caliper"

.

CAUTION:

When installing the caliper body to the torque member,
wipe any oil off of the knuckle spindle, washers and caliper
body attachment surfaces.

5.

Install brake hose by aligning with the protrusion on caliper
body, then install new copper washers and union bolt. Tighten
union bolt to specified torque. Refer to 

BR-26, "Hydraulic Cir-

cuit"

.

CAUTION:

Use new copper washers for installation.

6.

Refill with new brake fluid as necessary and bleed the air. Refer to 

BR-20, "Drain and Refill"

.

CAUTION:

• Refill with new brake fluid. 
• Do not reuse drained brake fluid.

7.

Install the front wheel and tire. Refer to 

WT-48, "Rotation"

.

LFIA0239E

SFIA1137E

2009 Pathfinder