Nissan PULSAR N13 Series / ASTRA LD Series. Manual - part 45

Brakes

 

181

 

 

chor plate to the steering knuckle and slide the caliper 
off the brake disc. Suspend the caliper clear of the 
work area using wire or cord.

 

(3) 

Suitably mark the location of the disc in 

relation to the hub.

 

(4)  Slide the disc off the hub. If the disc is 

difficult to remove, install two M8 x 1.25 mm bolts in 
the disc and by alternatively tightening the bolts, 
remove the disc.

 

Do not use a hammer to remove the disc.

 

Installation is a reversal of the removal procedure 

ensuring that the mating faces of the disc and hub are 
clean and free from burrs and that the marks made on 
removal are aligned.

 

To Inspect

 

(1)  Inspect the machined faces of the disc for 

scores, cracks, wear and signs of overheating. 

(2)  Using a micrometer, measure the thickness 

of the disc at several positions around the face of the 
disc. Renew the disc if the minimum thickness is 
below Specifications. 

 

Inspect the brake discs for scoring and wear

. 

(3) If the disc thickness is satisfactory but the 

disc is scored, machine equal amounts from the 
machined face on each side of the disc, to restore the 
serviceability of the disc.

 

NOTE: Disc machining is best entrusted to 
a reliable brake specialist who can advise on 
disc serviceability.

 

6.    REAR DISC BRAKES 

Special Equipment Required: 

To Check Disc Runout — Dial gauge 
To Check Disc Thickness — Micrometer 

TO CHECK AND RENEW BRAKE PADS 

(1) Raise the rear of the vehicle and place it on 

chassis stands. Remove the rear wheels.

 

 

Renew the rear brake pads if the friction material is less 

than 2 mm thick. 

(2)  Inspect the brake pads on both sides of the 

vehicle. If the friction material on one or more of the 
pads is less than 2 mm thick or contaminated with 
fluid or grease, renew the brake pad as a set as follows.

 

NOTE: If the brake pads are contaminated 
trace and rectify the cause prior to installing 
the new set of pads.

 

(3)  Drain approximately two thirds of the brake 

fluid from the master cylinder reservoir. This can be 
done by loosening the bleeder valve on the caliper and 
allowing the fluid to drain into a container. Discard 
this fluid.

 

NOTE: Do not drain all the fluid from the 
reservoir otherwise it will be necessary to 
bleed the hydraulic system. The fluid is 
drained from the reservoir to prevent over- 
flow when the caliper piston is pushed back 
into the caliper bore to facilitate pad re- 
newal.

 

(4)  Remove the guide bolts and lift the caliper 

body clear of the disc.

 

NOTE: Do not allow the caliper to hang on 
the brake hose.

 

(5)  Noting the installed positions, remove the 

brake pads, shims and spring clips from the anchor 
plate. 

(6)  Using a pair of long nosed pliers with the 

nose located in the recesses of the piston, rotate the 
piston clockwise to retract it into the cylinder body. 
Align the recesses between the brake pad retaining 
lugs on the caliper body. Refer to the illustration. 

(7)  If necessary,   check the  disc  runout  and 

thickness as described under the Brake Disc heading. 

(8)  Ensure that the guide bolts move freely in the 

caliper body and  that the dust boots are in good 
condition. 

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Brakes

 

 

 

Illustration of the rear disc caliper showing the correct 

piston alignment.

 

(9)  Install the brake pads, shims and spring 

clips 
in the position noted on removal. 

(10)  Install the caliper body to its original posi- 

tion. Lubricate the guide bolts with suitable grease. 
Install and tighten the guide bolts to the specified 
torque. 

(11)  Repeat the procedure on the opposite rear 

brake assembly. 

(12)  Replenish the master cylinder reservoir with 

the recommended fluid to the correct level and pump 
the brake pedal several times to locate the disc pads. 

(13)  Install the rear wheels and lower the vehicle 

to the ground. 

(14)  Road test the vehicle and check for correct 

brake operation. 

CALIPER

 

To Remove and Install

 

(1)  Raise the rear of the vehicle and place it on 

chassis stands. Remove the relevant rear wheel. 

(2)  Remove the brake hose retaining bolt from 

the caliper body and plug the hose to prevent the 
loss of fluid and the ingress of dirt. 

 

Installed view of the rear brake caliper. 

(3)  Remove the handbrake cable bracket retain- 

ing bolts and disconnect the handbrake cable from the 
cam lever. 

(4)  Remove the bolts retaining the caliper an- 

chor plate. Remove the caliper from the disc. 

Installation is a reversal of the removal procedure 

with attention to the following points:

 

(1)  Tighten the caliper anchor plate bolts to the 

specified torque. 

(2)  Install the brake hose to the caliper body 

ensuring that new seal washers are installed. 

NOTE: Ensure that the brake hose locating 
pin is correctly installed in the caliper body.

 

de-

 

(3)  Bleed the brake hydraulic system as 

scribed under the Hydraulic System heading. 

(4)  Install the rear wheel and lower the vehicle to 

the ground. 

(5)  Road test the vehicle and check for correct 

brake operation. 

 

Dismantled view of the rear brake caliper 

Brakes

 

183

 

 

To Dismantle

 

(1)  Raise the rear of the vehicle and place it on 

chassis stands. Remove the relevant rear wheel. 

(2)  Remove the brake hose retaining bolt from 

the caliper body and plug the hose to prevent the loss 
of fluid and the ingress of dirt. 

(3)  Remove the handbrake cable bracket retain- 

ing bolt and disconnect the handbrake cable from the 
cam lever. 

(4)  Remove the guide bolts and slide the caliper 

body off the pads. 

(5)  Using a pair of long nose pliers with the nose 

located in the recesses of the piston, rotate the piston 
anticlockwise to remove it from the caliper body. 

(6)  Remove the dust cover retaining clip and dust 

cover. Discard the dust cover. 

(7)  Using a thin blunt probe, preferably made 

from wood or plastic, remove and discard the piston 
seal from the groove in the caliper bore. 

(8)  Using internal snap ring pliers, remove the 

snap ring from the caliper bore. 

(9)  Withdraw the spring cover, spring, key plate, 

pushrod and link from the caliper bore. Do not mix 
these components from the left and right hand sides as 
they differ. 

(10) Remove and discard the O ring from the 

pushrod. 

(11)  Remove the spring, nut and washer from the 

cam lever. Remove the cam lever and cam from the 
caliper body. 

(12)  Remove the cam seal from the caliper using a 

screwdriver. 

(13)  Clean all the caliper components in methy- 

lated spirits and arrange the components in order on a 
clean dry surface to aid assembly. 

To Inspect

 

(1)  Inspect the caliper bore and piston for pit- 

ting, wear or damage. Renew the caliper assembly or 
piston if damage is evident.

 

NOTE: Slight rust spots in the caliper bore 
may be removed with fine emery paper. The 
piston must not be polished as the plated 
surface will be damaged.

 

(2)  Inspect the guide bolts for wear or damage 

and renew as necessary. 

(3)  Inspect the threads of the pushrod for wear or 

damage and renew as necessary. 

(4)  Inspect the nut inside the piston for wear, 

damage and security. Renew the piston if any damage 
is evident. 

(5)  Inspect the cam for wear, damage or pitting, 

renew as necessary. 

(6)  Inspect the cam bearing in the caliper body 

for wear, damage or pitting and renew the seal and 
bearing as necessary. 

(7)  Inspect the guide bolt rubbers for deteriora- 

tion, wear or damage. Renew as required. 

To Assemble

 

(1)  Lubricate the cam bearing with multipurpose 

grease and install the seal. 

(2)  Install the cam and cam lever to the 

caliper 
body. Install the cam lever spring, washer and nut, and 
tighten the nut to the specified torque. 

(3)  Install a new O ring to the pushrod and 

install 
the link, pushrod, key plate, spring and spring cover to 
the caliper body. The key plate must engage the caliper 
body. Secure the assembly with the snap ring. 

(4)  Dip a new piston seal in clean hydraulic brake 

fluid. Insert the seal into the groove in the caliper bore 
ensuring that the seal is correctly seated and not 
twisted. 

(5)  Install a new dust cover to the piston prior 

to 
installing the piston to the caliper bore. 

(6)  Coat the piston and caliper bore with clean 

hydraulic brake fluid and using long nose pliers rotate 
the piston clockwise into the caliper bore. 

(7)  Locate the dust seal in the groove of the 

caliper body and install the retaining clip. 

(8)  Lubricate the guide bolts using a suitable 

grease. Install the caliper body and tighten the guide 
bolts to the specified torque. 

(9)  Replenish the master cylinder reservoir with 

the recommended fluid and bleed the brakes as 
described under the Hydraulic System heading. 

(10) Install the rear wheel and lower the vehicle to 

the ground. 

(11)  Road test the vehicle and check for correct 

brake operation. 

BRAKE DISC

 

To Check Runout

 

(1)  Raise the rear of the vehicle and support it on 

chassis stands. Remove the relevant rear wheel. 

(2)  Mount a dial gauge stand to a suspension 

component and position the dial gauge plunger 
against the wheel hub. Check that the end float is less 

 

Using a dial gauge to measure the rear disc runout.

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Brakes

 

 

than 0.05 mm. If the wheel hub end float exceeds 
Specifications, the bearing must be renewed as de- 
scribed in the Rear Suspension section.

 

(3)  Position the dial gauge plunger against the 

centre of the brake disc contact area. Rotate the hub 
and measure the runout. Maximum allowable runout 
is 0.07 mm. 

(4)  If the runout exceeds the specified amount, 

machine or renew the brake disc. 

(5)  Install the rear wheel and lower the vehicle to 

the ground. 

(6)  Road test the vehicle and check for correct 

brake operation. 

To Remove and Install

 

(1)  Raise the rear of the vehicle and support it 

on chassis stands. Remove the relevant rear wheel. 

(2)  Remove the clip securing the brake hose to 

the suspension unit and disengage the hose. 

(3)  Remove the bolts retaining the caliper an- 

chor plate. 

(4)  Slide the caliper from the brake disc and 

suspend the caliper clear of the work area using wire 
or cord. 

NOTE: Do not allow the caliper to hang on 
the brake hose.

 

(5)  Remove the grease cap from the rear hub. 
(6)  Remove the split pin, nut retainer, hub nut 

and washer from the stub axle. 

(7)  Remove the hub assembly from the stud 

axle. 

Installation is a reversal of the removal procedure 

with attention to the following points:

 

(1)  Tighten the rear hub to the specified torque. 
(2)  Install the brake caliper and tighten all the 

bolts to the specified torque. 

(3)  Rotate the hub and check for roughness. If 

the hub does not rotate smoothly, renew the hub 
bearing as described in the Rear Suspension section. 

(4)  Install the rear wheel and lower the vehicle to 

the ground. 

(5)  Road test the vehicle and check for correct 

brake operation. 

To Inspect

 

(1)  Inspect the machined faces of the disc for 

scores, cracks, wear and signs of overheating. 

(2)  Using a micrometer, measure the thickness 

of the disc at several positions around the face of the 
disc. Renew the disc if the minimum thickness is 
below Specifications.

 

(3)  If the disc thickness is satisfactory but the 

disc is scored,  machine equal amounts  from the 
machined face on each side of the disc, to restore the 
serviceability of the disc.

 

 

Inspect the machined faces of the disc for scores, 

cracks, wear and signs of overheating. 

NOTE: Disc machining is best entrusted to 
a reliable brake specialist who can advise on 
disc serviceability.

 

7.    REAR DRUM BRAKES

 

TO REMOVE AND DISMANTLE

 

(1)  Raise the rear of the vehicle and support it 

on chassis stands. Remove the rear wheels and release 
the handbrake. 

(2)  Remove the grease cap from the rear hub. 
(3) 

Remove the split pin, nut retainer, hub nut 

and washer from the stub axle. Remove the brake 
drum and hub assembly.

 

(4)  Mark each brake shoe and spring to ensure 

correct assembly. 

(5)  Rotate the  star wheel  until  the  adjuster 

assembly is at its shortest length. 

Installed view of the left hand side rear drum brake

components.