Nissan Pathfinder (2009 year). Manual - part 95

BR-42

< ON-VEHICLE REPAIR >

REAR DISC BRAKE

REAR DISC BRAKE

Exploded View of Brake Pad

INFOID:0000000004391560

Rear 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 inner and outer shims 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-43, "Brake Burnishing"

.

Removal and Installation of Brake Pad

INFOID:0000000004391561

REMOVAL

1.

Remove the rear wheel and tire. Refer to 

WT-48, "Rotation"

.

2.

Remove the master cylinder reservoir cap.

AWFIA0469ZZ

1.

Inner shim

2.

Upper pad retainer

3.

Inner brake pad

4.

Outer brake pad

5.

Lower pad retainer

6.

Outer shim

A.

Molykote 7439 grease

B.

Molykote M-77 grease

2009 Pathfinder

REAR DISC BRAKE

BR-43

< ON-VEHICLE REPAIR >

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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 rear brake hose.

5.

Remove the rear inner and outer brake pads, shims and retainers from the torque member.

INSTALLATION

1.

Apply Molykote M-77 grease between the brake pad back plates and shims, then attach the shims to the
brake pads.

2.

Apply Molykote 7439 grease (A) to the pad retainers as shown

3.

Attach pad retainer to torque member, then install brake pad and
shim assemblies.

CAUTION:

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

4.

Using a suitable tool push piston into caliper body.

CAUTION:

By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
NOTE:
Use a suitable tool to make it easier to push the piston into the caliper body.

5.

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

6.

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

BR-44, "Exploded View of Brake Cal-

iper"

.

7.

Check the brakes for drag.

8.

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

9.

Install the rear wheel and tire. Refer to 

WT-48, "Rotation"

.

Brake Burnishing

INFOID:0000000003937517

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.

AWFIA0039ZZ

PFIA0273E

2009 Pathfinder

BR-44

< ON-VEHICLE REPAIR >

REAR DISC BRAKE

Exploded View of Brake Caliper

INFOID:0000000003937515

Rear 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-43, "Brake Burnishing"

.

Removal and Installation of Brake Caliper and Disc Rotor

INFOID:0000000003937516

REMOVAL

1.

Remove the rear wheel and tire. Refer to 

WT-48, "Rotation"

.

2.

Drain the brake fluid. Refer to 

BR-20, "Drain and Refill"

.

AWFIA0471GB

1.

Union bolt

2.

Brake hose

3.

Copper washers

4.

Sliding pin bolt

5.

Cap

6.

Bleed valve

7.

Caliper body

8.

Sliding pin

9.

Piston seal

10. Piston

11. Piston boot

12. Torque member

13. Torque member bolt

14. Sliding pin boot

R.

Rubber grease

2009 Pathfinder

REAR DISC BRAKE

BR-45

< ON-VEHICLE REPAIR >

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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
torque member.

5.

Remove the brake pads, shims 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-44, "Exploded

View of Brake Caliper"

.

3.

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

BR-42, "Exploded View of

Brake Pad"

.

4.

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

BR-

44, "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.

LFIA0211E

SDIA2638E

SDIA2638E

2009 Pathfinder

BR-46

< ON-VEHICLE REPAIR >

REAR DISC BRAKE

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 rear wheel and tire. Refer to 

WT-48, "Rotation"

.

SFIA1137E

2009 Pathfinder

BRAKE MASTER CYLINDER

BR-47

< DISASSEMBLY AND ASSEMBLY >

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DISASSEMBLY AND ASSEMBLY

BRAKE MASTER CYLINDER

Disassembly and Assembly

INFOID:0000000003937518

Brake Master Cylinder

DISASSEMBLY

CAUTION:

• Master cylinder sub-assembly cannot be disassembled.
• Remove reservoir tank only when absolutely necessary.
• While working, cover the primary piston rod with a cloth to prevent it from being damaged.
• 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.

AWFIA0462GB

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

11.

Pin

A.

PBC (Poly Butyl Cuprysil) grease 
or silicone based grease

B.

Brake fluid

R.

Rubber grease

Front

2009 Pathfinder

BR-48

< DISASSEMBLY AND ASSEMBLY >

BRAKE MASTER CYLINDER

1.

Secure the flange of the master cylinder sub-assembly in a vise.

CAUTION:

• Use copper plates or a cloth to cover the flange before

securing it in the vise.

• When securing the master cylinder sub-assembly in a

vise, be sure not to over-tighten the vise.

2.

Remove the pin and pull the reservoir tank off of the master cylinder sub-assembly.

3.

Remove the grommets from the master cylinder sub-assembly body.

CAUTION:

Do not reuse grommets.

4.

Remove the restriction washer from the master cylinder sub-assembly body.

CAUTION:

Do not reuse restriction washer.

5.

Remove the fluid level sensor.

6.

Remove the fluid pressure sensor.

CAUTION:

Do not reuse fluid level pressure sensor.

ASSEMBLY

Assembly is in the reverse order of disassembly.

CAUTION:

• Master cylinder sub-assembly cannot be disassembled.
• Remove reservoir tank only when absolutely necessary.
• While working, cover the primary piston rod with a cloth to prevent it from being damaged.
• 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.

BRA0558D

2009 Pathfinder

FRONT DISC BRAKE

BR-49

< DISASSEMBLY AND ASSEMBLY >

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FRONT DISC BRAKE

Exploded View of Brake Caliper

INFOID:0000000004414834

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"

.

Disassembly and Assembly

INFOID:0000000003937520

DISASSEMBLY

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