F BRAKES

SECTION
BRAKE SYSTEM
BR B

E
CONTENTS
PRECAUTIONS .......................................................... 3 REMOVAL ........................................................... 14 BR
Precautions for Supplemental Restraint System INSTALLATION ................................................... 15
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- Disassembly and Assembly .................................... 15
SIONER” .................................................................. 3 DISASSEMBLY ................................................... 15 G
Precautions for Brake System .................................. 3 ASSEMBLY ......................................................... 15
PREPARATION ........................................................... 4 BRAKE BOOSTER ................................................... 16
Special Service Tool ................................................. 4 On-Vehicle Service ................................................. 16
H
Commercial Service Tools ........................................ 4 OPERATING CHECK .......................................... 16
NOISE, VIBRATION, AND HARSHNESS (NVH) AIRTIGHT CHECK .............................................. 16
TROUBLESHOOTING ................................................ 5 Removal and Installation ........................................ 17
NVH Troubleshooting Chart ..................................... 5 REMOVAL ........................................................... 17 I
BRAKE PEDAL .......................................................... 6 INSTALLATION ................................................... 18
Inspection and Adjustment ....................................... 6 VACUUM LINES ....................................................... 19
INSPECTION ........................................................ 6 Removal and Installation ........................................ 19 J
ADJUSTMENT ...................................................... 6 Inspection ............................................................... 19
Removal and Installation .......................................... 7 VISUAL INSPECTION ......................................... 19
COMPONENTS .................................................... 7 CHECK VALVE INSPECTION ............................. 20
K
REMOVAL ............................................................. 7 FRONT DISC BRAKE ............................................... 21
INSPECTION AFTER REMOVAL ......................... 8 On-vehicle Inspection ............................................. 21
INSTALLATION ..................................................... 8 PAD WEAR INSPECTION ................................... 21
BRAKE FLUID ............................................................ 9 Components ........................................................... 22 L
On-board Inspection ................................................. 9 Removal and Installation of Brake Pad .................. 23
LEVEL CHECK ..................................................... 9 REMOVAL ........................................................... 23
Drain and Refill ......................................................... 9 INSTALLATION ................................................... 23 M
Bleeding Brake System .......................................... 10 Removal and Installation of Brake Caliper Assembly
BRAKE PIPING AND HOSE .....................................11 and Disc Rotor ........................................................ 23
Hydraulic Circuit ......................................................11 REMOVAL ........................................................... 23
Removal and Installation of Front Brake Piping and INSTALLATION ................................................... 23
Brake Hose .............................................................11 Disassembly and Assembly of Brake Caliper
REMOVAL ............................................................11 Assembly ................................................................ 24
INSTALLATION ................................................... 12 DISASSEMBLY ................................................... 24
Removal and Installation of Rear Brake Piping and CALIPER INSPECTION ...................................... 25
Brake Hose ............................................................ 12 ASSEMBLY ......................................................... 25
REMOVAL ........................................................... 12 DISC ROTOR INSPECTION ............................... 26
INSTALLATION ................................................... 12 BRAKE BURNISHING PROCEDURE ................. 27
Inspection After Installation .................................... 13 REAR DISC BRAKE ................................................. 28
BRAKE MASTER CYLINDER .................................. 14 On-vehicle Inspection ............................................. 28
On-board Inspection ............................................... 14 PAD WEAR INSPECTION ................................... 28
LEAK INSPECTION ............................................ 14 Components ........................................................... 28
Removal and Installation ........................................ 14 Removal and Installation of Brake Pad .................. 29

Revision: November 2005 BR-1 2005 Frontier

 REMOVAL ........................................................... 29 Assembly ................................................................30
INSTALLATION .................................................... 29 DISASSEMBLY ....................................................30
Removal and Installation of Brake Caliper Assembly CALIPER INSPECTION .......................................30
and Disc Rotor ........................................................ 29 ASSEMBLY ..........................................................31
REMOVAL ........................................................... 29 DISC ROTOR INSPECTION ...............................31
INSTALLATION .................................................... 29 BRAKE BURNISHING PROCEDURE .................32
Disassembly and Assembly of Brake Caliper SERVICE DATA AND SPECIFICATIONS (SDS) ......33
General Specifications ............................................33
Brake Pedal ............................................................33
Brake Booster .........................................................34
Front Disc Brake .....................................................34
Rear Disc Brake ......................................................34

Revision: November 2005 BR-2 2005 Frontier

 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS004YT

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING: D
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer. E
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. BR
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
G
Precautions for Brake System EFS004YU

● Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to MA-11,
"RECOMMENDED FLUIDS AND LUBRICANTS" . H
● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
I
● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.
● Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
● Use flare nut wrench when removing and installing brake tube. J
● Always check tightening torque when installing brake lines.
● Before working, turn ignition switch to OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery K
terminals.
● Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal L
occurs at very low mileage.
Refer to BR-27, "BRAKE BURNISHING PROCEDURE" .
WARNING:
● Clean brake pads and shoes with a waste cloth, then wipe
SBR686C M
with a dust collector.

Revision: November 2005 BR-3 2005 Frontier

 PREPARATION

PREPARATION PFP:00002

Special Service Tool EFS004YV

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
— Measuring brake pedal height
(J-46532)
Brake and clutch pedal height measure-
ment tool

LFIA0227E

Commercial Service Tools EFS004YW

Tool name Description

1. Flare nut crowfoot Removing and installing each brake pip-
2. Torque wrench ing
a: 10 mm (0.39 in) / 12 mm (0.47 in)

S-NT360

Power tool Removing nuts, bolts and screws

PBIC0190E

PBIC0191E

Revision: November 2005 BR-4 2005 Frontier

 Symptom

×: Applicable
Reference page

Noise
Shake
Possible cause and
SUSPECTED PARTS

Revision: November 2005

Shimmy, Shudder
Pads - damaged BR-21, BR-28

×
×
Pads - uneven wear BR-21, BR-28
NVH Troubleshooting Chart

×
Shims damaged BR-22, BR-28

×
×
Rotor imbalance BR-26, BR-31

Rotor damage BR-26, BR-31

×
×
Rotor runout BR-26, BR-31

BR-5
×
Rotor deformation BR-26, BR-31

×
Rotor deflection BR-26, BR-31

×
Rotor rust BR-27, BR-32

×
Rotor thickness variation BR-27, BR-32

×
×
PROPELLER SHAFT PR-3, "NVH Troubleshooting Chart"

FFD-6, "NVH Troubleshooting Chart" (FFD)

RFD-8, "NVH Troubleshooting Chart" (RFD, C200)

×
DIFFERENTIAL
RFD-42, "NVH Troubleshooting Chart" (RFD, M226 without LD)
RFD-76, "NVH Troubleshooting Chart" (RFD, M226 with LD)
FAX-4, "NVH Troubleshooting Chart" (FAX)

×
×
× DRIVESHAFT RAX-5, "NVH Troubleshooting Chart" (RAX, C200)
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

RAX-17, "NVH Troubleshooting Chart" (RAX, M226)

× SUSPENSION FSU-4, "NVH Troubleshooting Chart" (FSU)

×
×

RSU-4, "NVH Troubleshooting Chart" (RSU)

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

×
×
×

TIRES AND ROAD WHEEL WT-3, "NVH Troubleshooting Chart"

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×

STEERING PS-5, "NVH Troubleshooting Chart"

2005 Frontier
EFS004YX
PFP:00003

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS004YY

INSPECTION
1. Inspect the brake pedal free height "H" from dash lower using
Tool.
Tool : — (J-46532)
2. Adjust the height referring to the following specifications.

WFIA0160E

Unit: mm (in)

Free height "H" A/T : 182.1 - 192.1 (7.17 - 7.56)

M/T : 174.7 - 184.7 (6.88 - 7.27)
Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb) : 103 - 123 (4.06 - 4.84)
with engine running]
Clearance between pedal stopper and threaded end of stop lamp : 0.74 - 1.96 mm (0.029 - 0.077 in)
switch and ASCD switch "C1 " or "C2 "

Pedal play "A" : 3 - 11 mm (0.12 - 0.43 in)

ADJUSTMENT
1. Loosen the stop lamp switch and ASCD switch by turning 45° counterclockwise.
2. Loosen lock nut on the input rod, then turn input rod to adjust the
pedal to specified height. When finished adjusting, tighten lock
nut.
CAUTION:
Make sure that the screw portion of the end of input rod is
located inside the clevis.
Lock nut : 18.6 N·m (1.9 kg-m, 14 ft-lb)
3. With the pedal pulled up and held by hand, press the stop lamp
switch and the ASCD switch in until threaded ends contact pedal
arm. SBR229E

4. With the threaded ends of the stop lamp switch and ASCD
switch contacting the pedal arm, turn the switches 45° clockwise to lock in place.

Revision: November 2005 BR-6 2005 Frontier

 BRAKE PEDAL

CAUTION:
Make sure that the gap "C1 or C2 " between the rubber stops and switch ends are within specifica- A
tion.
5. Check the pedal play.
CAUTION: B
Make sure that the stop lamp goes off when the pedal is released.
6. Start the engine and check the height of the brake pedal when depressing it.
C
Removal and Installation EFS004YZ

COMPONENTS
D

BR

LFIA0232E M
1. Brake pedal assembly 2. Snap pin 3. Clip
4. Stop lamp switch 5. Pedal pad 6. Clevis pin
7. ASCD cancel switch

REMOVAL
WARNING:
Do not deform the brake tube.
CAUTION:
● Do not disassemble the brake pedal assembly.
● Avoid damage from dropping the brake pedal assembly during handling.
● Keep the brake pedal assembly away from water.
1. Remove the lower driver instrument panel. Refer to IP-10, "Removal and Installation" .
2. Remove the stop lamp switch and ASCD switch from the pedal assembly.
3. Remove snap pin and clevis pin from the clevis of the brake booster.
4. Remove mounting nuts and the pedal assembly.

Revision: November 2005 BR-7 2005 Frontier

 BRAKE PEDAL

● Temporarily install the nuts by hand to support the booster.

INSPECTION AFTER REMOVAL
Check brake pedal for following items.
● Crack or deformation of clevis pin stopper
● Clevis pin deformation
● Crack of any welded portion
● Brake pedal bend

SBR997

INSTALLATION
1. Installation is in the reverse order of removal.
● Check the brake pedal for smooth operation. There should be no binding or sticking when applying or
releasing the brake pedal.
● After installing the brake pedal assembly in the vehicle, be sure to adjust it. Refer to BR-6, "Inspection
and Adjustment" .

Revision: November 2005 BR-8 2005 Frontier

 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
On-board Inspection EFS004Z0

LEVEL CHECK
● Check that the brake fluid level in the reservoir tank is within B
specification, between the MAX and MIN lines as shown.
● Visually check around reservoir tank for fluid leaks.
● If fluid level is excessively low, check brake system for leaks. C
● If brake warning lamp remains illuminated after the parking
brake pedal is released, check the brake system for any brake
fluid leaks.
D

LFIA0234E
E
Drain and Refill EFS004Z1

CAUTION:
● Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . BR
● Do not reuse drained brake fluid.
● Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
G
when splashing it, immediately wipe off the area and wash away with water.
● Before servicing, disconnect actuator connector or battery negative cable.
1. Connect a vinyl tube to each bleed valve. H
2. Depress brake pedal, loosen each bleed valve, and gradually
remove brake fluid.
I

K
SBR419C

3. Make sure there is no foreign material in reservoir tank, and refill L

with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal. M
Repeat this process a few times, then pause to add new brake
fluid to master cylinder. Continue until new brake fluid flows out.
Bleed air from brake system. Refer to BR-10, "Bleeding Brake
System" .

SBR995

Revision: November 2005 BR-9 2005 Frontier

 BRAKE FLUID

Bleeding Brake System EFS004Z2

CAUTION:
While bleeding, monitor the master cylinder brake fluid level.
1. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector or battery
negative cable.
2. Connect a vinyl tube to the rear right bleed valve.
3. Fully depress brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
5. Repeat steps 3 and 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-22, "Components" (front disc brake), BR-28,
"Components" (rear disc brake).
7. Perform steps 2 to 6 at each wheel, with master cylinder reservoir tank filled at least half way, bleed air
from the front left, rear left, and front right bleed valve, in that order.

Revision: November 2005 BR-10 2005 Frontier

 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

A
Hydraulic Circuit EFS004Z3

BR

G
WFIA0345E

1. Actuator 2. Master cylinder 3. Brake booster

4. Connector H
CAUTION:
● All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.
● Make sure there is no interference with other parts when turning steering both clockwise and I
counterclockwise.
● The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble
the parts. Replace applicable part with a new one, if necessary. J
● Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
● Do not bend or twist brake hose sharply, or strongly pull it. K
● When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.
● Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . L
● Do not reuse drained brake fluid.
Removal and Installation of Front Brake Piping and Brake Hose EFS004Z4
M
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove union bolt and then remove brake hose from caliper assembly.

Revision: November 2005 BR-11 2005 Frontier

 BRAKE PIPING AND HOSE

INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt to the specified torque. Refer to
BR-11, "Hydraulic Circuit" .
NOTE:
Do not reuse copper washer.

LFIA0235E

2. Insert brake hose end through bracket, then secure it to bracket

with lock plate.
3. Install brake tube to brake hose, then tighten flare nut to the
specified torque using a flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake
System" .

LFIA0236E

Removal and Installation of Rear Brake Piping and Brake Hose EFS004Z5

REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt to the specified torque. Refer to
BR-11, "Hydraulic Circuit" .
NOTE:
Do not reuse copper washer.

LFIA0237E

2. Insert brake hose end through bracket, then secure it to bracket

with lock plate.
3. Install brake tube to brake hose, then tighten flare nut to the
specified torque using a flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake
System" .

LFIA0238E

Revision: November 2005 BR-12 2005 Frontier

 BRAKE PIPING AND HOSE

Inspection After Installation EFS004Z6

A
CAUTION:
If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact
with other parts, and loose connections. Replace any damage parts. B
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately
5 seconds, check for fluid leaks from each part.
C

BR

Revision: November 2005 BR-13 2005 Frontier

 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

On-board Inspection EFS004Z7

LEAK INSPECTION
● Check for leaks at master cylinder to brake booster attachment point, reservoir tank, and brake tube con-
nections.
Removal and Installation EFS004Z8

Brake Master Cylinder

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

CAUTION:
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Disconnect harness connectors for fluid level sensor and pressure sensor.
Revision: November 2005 BR-14 2005 Frontier
 BRAKE MASTER CYLINDER

3. Using a flare nut wrench, disconnect brake tube from master cylinder assembly.
4. Remove master cylinder assembly mounting nuts and master cylinder assembly. A

INSTALLATION
● Installation is in the reverse order of removal. B
● Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
CAUTION:
● Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
C
● Do not reuse drained brake fluid.

● Adjust brake pedal. Refer to BR-6, "Inspection and Adjustment" .

Disassembly and Assembly EFS004Z9
D
DISASSEMBLY
CAUTION:
● Master cylinder cannot be disassembled. E
● 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. BR

ASSEMBLY
CAUTION: G
● Never use mineral oil such as kerosene, gasoline during the cleaning and assembly process.
● Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer H
to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
CAUTION:
Do not reuse grommet. I
2. Install reservoir tank onto master cylinder assembly.

Revision: November 2005 BR-15 2005 Frontier

 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

On-Vehicle Service EFS004ZA

OPERATING CHECK
With engine stopped, change the vacuum to the atmospheric pres-
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure the clearance between brake pedal
and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.

BRA0037D

AIRTIGHT CHECK
● Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure dis-
tance between brake pedal and floor panel gradually increases.
● Depress brake pedal while engine is running and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.
CAUTION:
Depressing pedal interval is approximately 5 seconds.

SBR365AA

Revision: November 2005 BR-16 2005 Frontier

 BRAKE BOOSTER

Removal and Installation EFS004ZB

A
Brake Booster

BR

LFIA0241E

1. Brake booster hose 2. Brake booster vacuum check valve 3. Brake booster
4. Lock nut 5. Gasket 6. Spacer block

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 dur-
ing installation, dash panel may damage the threads.
● Attach the check valve in the correct direction.

Revision: November 2005 BR-17 2005 Frontier

 BRAKE BOOSTER

1. Remove actuator and electric unit. Refer to BRC-40, "Removal and Installation" (ABS), BRC-86,
"Removal and Installation" (ABLS/ABS) and BRC-154, "Removal and Installation" (HDC/HSA/VDC/TCS/
ABS).
2. Remove brake piping from brake master cylinder.
3. Remove brake master cylinder. Refer to BR-14, "Removal and Installation" .
4. Remove vacuum hose from brake booster. Refer to BR-19, "Removal and Installation" .
5. Remove brake pedal attachment snap pin and clevis pin from inside the vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster assembly from dash panel.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length "B"
(in the figure) satisfies the specified value.
Length "B" : 150 mm (5.91 in)
2. After adjusting "B", temporarily tighten lock nut and install
booster assembly to the vehicle.
● Install a gaskets and spacer block between booster assembly
and the dash panel.
3. Connect brake pedal with clevis of input rod.
4. Install brake booster mounting nuts and tighten them to the
SGIA0060E
specified torque.
5. Install brake piping from brake master cylinder to actuator and electric unit. Refer to BR-11, "Hydraulic Cir-
cuit" .
6. Connect vacuum hose to brake booster.
7. Install master cylinder to booster assembly. Refer to BR-14, "Removal and Installation" .
8. Adjust the brake pedal height. Refer to BR-6, "Inspection and Adjustment" .
9. Tighten lock nut of input rod to the specified torque.
10. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .

Revision: November 2005 BR-18 2005 Frontier

 VACUUM LINES

VACUUM LINES PFP:41920

A
Removal and Installation EFS004ZC

Brake Booster Vacuum Hose

B

BR

WFIA0332E

1. Brake booster hose 2. Brake booster hose clip 3. Brake booster vacuum check valve
H
1. Disconnect brake booster hose from hose clip mounted on bracket.
2. Release hose clips and disconnect brake booster hose.
3. Remove check valve from brake booster. I
4. Installation is in the reverse order of removal.
CAUTION:
● Insert vacuum hose for at least 24 mm (0.94 in).
J
● Do not use lubricating oil during assembly.

M
SBR225B

Inspection EFS004ZD

VISUAL INSPECTION
Check for improper assembly, damage and deterioration.

Revision: November 2005 BR-19 2005 Frontier

 VACUUM LINES

CHECK VALVE INSPECTION

Airtightness Inspection
Use a suitable vacuum pump to check. Connect to brake booster
side of check valve.
Check : Vacuum decrease should be within 1.3
valve kPa (10 mmHg, 0.39 inHg) for 15 seconds
specifi- under a vacuum of – 66.7 kPa (– 500 mmHg,
cation – 19.69 inHg)

LFIA0217E

Revision: November 2005 BR-20 2005 Frontier

 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

A
On-vehicle Inspection EFS004ZE

PAD WEAR INSPECTION

● Inspect the thickness of pad through cylinder body inspection B
hole. Use a scale for inspection if necessary. Refer to BR-34,
"Front Disc Brake" .

BRA0010D
E

BR

Revision: November 2005 BR-21 2005 Frontier

 FRONT DISC BRAKE

Components EFS004ZF

Front Disc Brake Caliper and Pads

WFIA0461E

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. Pad retainer 11. Inner shim 12. Inner brake pad
13. Outer brake pad 14. Pad retainer 15. Outer shim
16. Bleed valve 17. Cap 18. Copper washers
19. Union bolt 20. Brake hose ← Front

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

Revision: November 2005 BR-22 2005 Frontier

 FRONT DISC BRAKE

CAUTION:
● While removing cylinder body never depress brake pedal because piston will pop out. A
● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose. B
● 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-27, "BRAKE BURNISHING PROCEDURE" . C
Removal and Installation of Brake Pad EFS004ZG

REMOVAL
1. Remove tires from vehicle using power tool. D
2. Remove brake master cylinder reservoir cap.
3. Remove lower sliding pin bolt.
E
4. Suspend cylinder body with a wire and remove pad and shim from torque member.
INSTALLATION
1. Apply Molykote AS880N grease between brake pad plate and shim, then attach shims to brake pads. BR
Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
2. Attach pad retainer to torque member, then install brake pad and
shim assemblies. G
CAUTION:
When attaching pad retainer, attach it firmly so that it is
flush with torque member, as shown.
H
3. Push pistons into cylinder body.
NOTE:
Using a disc brake piston tool (commercial service tool), etc.,
I
makes it easier to push in piston.
CAUTION:
PFIA0273E
By pushing in piston, brake fluid returns to master cylinder
reservoir tank. Watch the level of the surface of reservoir tank. J
4. Remove wire then swing cylinder body down over brake pad assemblies.
5. Install lower sliding pin bolt and tighten to specification. Refer to BR-22, "Components" .
K
6. Check brake for drag.
7. Inspect fluid level, then install master cylinder reservoir cap.
8. Install wheel and tire. L
Removal and Installation of Brake Caliper Assembly and Disc Rotor EFS004ZH

REMOVAL
1. Remove tires from vehicle using power tool. M
2. Drain brake fluid as necessary. Refer to BR-9, "Drain and Refill" .
NOTE:
Do not remove union bolt unless removing brake caliper assembly from vehicle.
3. Remove union bolt as necessary and torque member bolts, then remove brake caliper assembly from the
vehicle.
NOTE:
Position brake caliper assembly aside using suitable wire, as necessary.
NOTE:
When servicing brake caliper, remove sliding pin bolts and caliper from torque member.
4. Remove torque member.
5. Remove disc rotor.
INSTALLATION
CAUTION:
● Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
● Do not reuse drained brake fluid.
Revision: November 2005 BR-23 2005 Frontier
 FRONT DISC BRAKE

1. Install disc rotor.

2. Install sliding pin bolts and torque member to caliper, if removed. Refer to BR-22, "Components" .
3. Install caliper assembly to the vehicle, then tighten torque mem-
ber bolts to the specified torque. Refer to BR-22, "Components"
.
CAUTION:
When attaching caliper assembly to the vehicle, wipe any
oil off knuckle spindle, washers and caliper assembly
attachment surfaces.

LFIA0239E

4. Install brake hose to brake caliper assembly, if removed, then

tighten union bolt to the specified torque. Refer to BR-22, "Com-
ponents" .
CAUTION:
● Do not reuse copper washers for union bolt.

● Attach brake hose to caliper assembly together with

union bolt and washers.

LFIA0235E

5. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
6. Attach tires to the vehicle. Refer to WT-6, "Rotation" .
Disassembly and Assembly of Brake Caliper Assembly EFS004ZI

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.

BRB0032D

Revision: November 2005 BR-24 2005 Frontier

 FRONT DISC BRAKE

4. Using a flat-bladed screwdriver, remove piston seal from cylin-

der body. A
CAUTION:
● Be careful not to damage cylinder inner wall.

● Do not reuse piston seal. B

SFIA0141E

D
CALIPER INSPECTION
Cylinder Body
CAUTION: E
● Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.
● Check inside surface of cylinder for score, rust, wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.
BR
● 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 G
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
H
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
dition are observed.
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are I
stuck to sliding surface.
Sliding Pins, and Sliding Pin Boots
J
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part.
CAUTION:
K
Trailing/upper sliding pin must be replaced at each service.
ASSEMBLY
CAUTION: L
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 in to
groove on cylinder body. M
CAUTION:
Do not reuse piston seal.

SFIA2399E

Revision: November 2005 BR-25 2005 Frontier

 FRONT DISC BRAKE

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.

SFIA2432E

3. Apply brake fluid to piston, then install piston into cylinder body
and insert piston boot side lip in to groove of piston as shown.
CAUTION:
Press the piston evenly to prevent damage to cylinder wall.

WFIA0211E

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-22, "Components" .
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. Using wheel nuts, fix disc rotor to wheel hub. (two or more positions.)
2. Inspect runout using a dial gauge. (Measured at 10mm (0.39 in)
inside the disc edge.)
Runout limit (on vehicle) : 0.05 mm (0.0020 in)
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to FAX-5, "WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole. BRA0013D

4. If runout still out of specification, turn rotor with on-car brake

lathe.

Revision: November 2005 BR-26 2005 Frontier

 FRONT DISC BRAKE

Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is A
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor. Refer to BR-34, "Front Disc Brake" .
B

SBR020B
D

BRAKE BURNISHING PROCEDURE

Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after E
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.
BR
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.
G
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.
H

Revision: November 2005 BR-27 2005 Frontier

 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

On-vehicle Inspection EFS004ZJ

PAD WEAR INSPECTION

● Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary. Refer to BR-34,
"Rear Disc Brake" .

BRA0010D

Components EFS004ZK

Rear Disc Brake Caliper and Pads

WFIA0462E

1. Union bolt 2. Brake hose 3. Copper washers

4. Sliding pin bolt 5. Cap 6. Bleed valve

Revision: November 2005 BR-28 2005 Frontier

 REAR DISC BRAKE

7. Cylinder body 8. Sliding pin 9. Piston seal

10. Piston 11. Piston boot 12. Torque member A
13. Torque member bolt 14. Pad retainer 15. Outer shim
16. Outer brake pad 17. Inner brake pad 18. Inner shim
⇐ Front B

WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
C
particles or other materials.
CAUTION:
● While removing cylinder body, never depress brake pedal because piston will pop out.
D
● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
● Do not damage piston boot. E
● 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-32, "BRAKE BURNISHING PROCEDURE" .
BR
Removal and Installation of Brake Pad EFS004ZL

REMOVAL
1. Remove tires from vehicle with power tool. G
2. Remove mounting bolt from the top mount.
3. Swing cylinder body open, and remove pads.
INSTALLATION H
1. Push piston in so that pad is firmly attached and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston. I
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank. J
2. Install pads to cylinder body.
3. Install top mounting bolt and tighten to specification.
4. Check brake for drag. K
5. Install tires to the vehicle.
Removal and Installation of Brake Caliper Assembly and Disc Rotor EFS004ZM L
REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill" . M
3. Remove union bolt and mounting bolts, and remove brake cali-
per assembly.
4. Remove disc rotor.

LFIA0211E

INSTALLATION
CAUTION:
● Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
● Do not reuse drained brake fluid.
1. Install disc rotor.

Revision: November 2005 BR-29 2005 Frontier

 REAR DISC BRAKE

2. Install caliper assembly to the vehicle, and tighten mounting bolts to specification. Refer to BR-28, "Com-
ponents" .
CAUTION:
Before installing caliper assembly to the vehicle, wipe off mounting surface of caliper assembly.
3. Install brake hose to caliper assembly and tighten union bolt to specification. Refer to BR-28, "Compo-
nents" .
CAUTION:
● Do not reuse copper washer for union bolt.

● Securely attach brake hose to protrusion on caliper assembly.

4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper Assembly EFS004ZN

DISASSEMBLY
1. Remove pads from cylinder body.
2. Remove sliding sleeve and boot from cylinder body.
3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Do not get your fingers caught in piston.

BRD0041D

4. Using a flat-bladed screwdriver, remove piston seal from cylin-

der body.
CAUTION:
Be careful not to damage cylinder inner wall.

PFIA0269E

CALIPER INSPECTION
Cylinder Body
CAUTION:
● Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
● 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
CAUTION:
● Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials
are stuck to sliding surface.
● Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above conditions are observed.

Revision: November 2005 BR-30 2005 Frontier

 REAR DISC BRAKE

Sliding Pin Bolts and Sliding Pin Boots

Make sure there is no wear, damage, or cracks in sliding sleeve and sliding sleeve boots, and if there are, A
replace them.
ASSEMBLY
B
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 in to
groove on cylinder body. C
CAUTION:
Do not reuse piston seal.
D

WFIA0210E
BR
2. Apply brake fluid to piston and to piston boot, then install piston
boot in to piston groove.
CAUTION: G
Do not reuse piston boot.

I
WFIA0211E

J
3. 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.
K
4. Install sliding boots and sleeves to cylinder body.
DISC ROTOR INSPECTION
Visual Inspection L
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.
Runout Inspection M
1. Using wheel nuts, install disc rotor to wheel hub. (2 or more positions.)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in)
inside disk edge.]
Runout limit (on vehicle) : 0.05 mm (0.0020 in)
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cation before measuring runout. Refer to RAX-6, "Rear Axle
Bearing" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole. BRA0013D

4. If runout still out of specification, turn rotor with on-car brake

lathe.

Revision: November 2005 BR-31 2005 Frontier

 REAR DISC BRAKE

Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor. Refer to BR-34, "Rear Disc Brake" .

SBR020B

BRAKE BURNISHING PROCEDURE

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.

Revision: November 2005 BR-32 2005 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications EFS004ZO

Unit: mm (in)
Engine QR25DE VQ40DE
B
Front brake Brake model CLZ33VB
Rotor outer diameter × thickness 296 × 28 (11.65 × 1.10)
Pad Length × width × thickness 140 × 49 × 10 (5.51 × 1.93 × 0.39) C
Cylinder bore diameter (Dual pis-
46.4 (1.83)
ton)
Rear brake Brake model CLZ11VA D
Rotor outer diameter × thickness 286 × 18 (11.26 × 0.71)
Pad Length × width × thickness 87.6 × 35 × 11 (3.45 × 1.38 × 0.43)
E
Cylinder bore diameter (Single pis-
38.1 (1.50)
ton)
Control valve Valve model EBD BR
Brake booster Booster model C215T

Diaphragm diameter 215 (8.46)

G
Recommended brake fluid Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .

Brake Pedal EFS004ZP

Unit: mm (in)
H

WFIA0160E

A/T 182.1 - 192.1 (7.17 - 7.56)

Free height "H"
M/T 174.7 - 184.7 (6.88 - 7.27)
Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb) with engine
103 - 123 (4.06 - 4.84)
running]
Clearance between pedal stopper and threaded end of stop lamp switch and
0.74 - 1.96 (0.029 - 0.077)
ASCD switch "C1 " or “C2 ”
Pedal play "A" 3 - 11 (0.12 - 0.43)

Revision: November 2005 BR-33 2005 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)

Brake Booster EFS004ZQ

Unit: mm (in)
Input rod installation standard dimension 15.6 − 15.9 (0.614 − 0.626)

Front Disc Brake EFS004ZS

QR25DE
Unit: mm (in)
Brake model CLZ33VB
Standard thickness (new) 10 (0.394)
Brake pad
Repair limit thickness 2 (0.079)
Standard thickness (new) 28 (1.10)
Repair limit thickness 26 (1.024)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.05 (0.0020)

VQ40DE
Unit: mm (in)
Brake model CLZ33VB
Standard thickness (new) 10 (0.394)
Brake pad
Repair limit thickness 2 (0.079)
Standard thickness (new) 28 (1.10)
Repair limit thickness 26 (1.024)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.05 (0.0020)

Rear Disc Brake EFS004ZT

Unit: mm (in)
Brake model CLZ11VA
Standard thickness (new) 11 (0.433)
Brake pad
Repair limit thickness 2 (0.079)
Standard thickness (new) 18 (0.71)
Repair limit thickness 16 (0.630)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.05 (0.0020)

Revision: November 2005 BR-34 2005 Frontier