1998 NISSAN PICK-UP Repair Manual

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
or caliper piston will pop out.
lBe careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
lIf shims are rusted or show peeling of the rubber coat,
replace them with new shims.
lIt is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to
stretch brake hose.
1. Remove master cylinder reservoir cap.
2. Remove lower pin bolt.
3. Open cylinder body upward. Then remove pad retainers,
return spring and inner and outer shims.
Standard pad thickness:
CL28VD model
10 mm (0.39 in)
Pad wear limit:
2.0 mm (0.079 in)
lCarefully monitor brake fluid level because brake fluid
will return to reservoir when pushing back piston.
SBR081A
SBR010B
FRONT DISC BRAKE
BR-21

Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch
brake hose.
Remove torque member fixing bolts and connecting bolt.
lIt is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend caliper assembly with wire so as not to
stretch brake hose.
SBR983D
SBR083A
FRONT DISC BRAKE
BR-22

Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
lDo not scratch or score cylinder wall.
lCL28VD type front disc brake uses plastic pistons,
handle them carefully.
1. Push out piston and dust cover with compressed air.
For CL28VD (2-piston type), use a wooden block so that both
pistons come out evenly.
2. Remove piston seal with a suitable tool.
Inspection Ð Caliper
CYLINDER BODY
lCheck inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign objects. If any of the above con-
ditions are observed, replace cylinder body.
lMinor damage from rust or foreign objects may be eliminated
by polishing the surface with a fine emery sandpaper.
Replace cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
PISTON
Ð for plastic piston (CL28VD) Ð
Check pistons for uneven surface, chips or cracks. Replace if
any of these conditions are observed.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks or other damage. Replace if any of these
conditions are observed.
Inspection Ð Rotor
RUNOUT
1. Check runout using a dial indicator.
lMake sure that wheel bearing axial end play is within the
specifications before measuring. Refer to FA section
(``Front Wheel Bearing'', ``ON-VEHICLE SERVICE'').
Maximum runout:
0.07 mm (0.0028 in)
2. If the runout is out of specification, machine rotor with on-car
brake lathe (``MAD, DL-8700'', ``AMMCO 700 and 705'' or
equivalent).
SBR085A
SBR177C
SBR089A
FRONT DISC BRAKE
BR-23

THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 in)
If thickness variation exceeds the specification, machine rotor
with on-car brake lathe.
Rotor repair limit:
CL28VD 24.0 mm (0.945 in)
Assembly
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot.
CAUTION:
lSecure dust seal properly.
lLubricate with new brake fluid before installing plastic
pistons (CL28VD) into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
Brake Burnishing Procedure
When experiencing soft brake pedal feel at very low mileage, or
after replacing the rotor, burnish the brake pad contact surfaces
according to the following procedures.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
SBR090A
SBR178C
SBR179CA
SBR084A
FRONT DISC BRAKE
Inspection Ð Rotor (Cont'd)
BR-24

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 the 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 bur-
nishing procedure.
FRONT DISC BRAKE
Brake Burnishing Procedure (Cont'd)
BR-25

SBR978D
SBR979D
REAR DRUM BRAKE
BR-26

Removal
WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Make sure parking brake lever is completely released.
1. Release parking brake lever fully, then remove drum.
lIf drum is hard to remove, the following procedures
should be carried out.
a. Remove plug. Then shorten adjuster to make clearance
between brake shoe and drum.
b. Install two bolts as shown. Tighten the two bolts gradu-
ally.
2. After removing retainer, remove spring by rotating shoes.
lBe careful not to damage wheel cylinder piston boots.
lBe careful not to damage parking brake cable when
separating it.
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.
5. Remove retainer clip with a suitable tool. Then separate
toggle lever and brake shoe.
SBR280B
SBR093A
ABR369
ABR408
REAR DRUM BRAKE
BR-27

Inspection Ð Wheel Cylinder
lCheck wheel cylinder for leakage.
lCheck for wear, damage and loose conditions.
Replace if any such conditions exists.
Wheel Cylinder Overhaul
lCheck all internal parts for wear, rust and damage. Replace
if necessary.
lPay attention not to scratch cylinder when installing pistons.
Inspection Ð Drum
Maximum inner diameter (Repair limit):
LT26B 261.5 mm (10.30 in)
LT30A 296.5 mm (11.67 in)
lContact surface should be finished with No. 120 to 150
emery sandpaper.
lUsing a brake lathe, machine brake drum if it shows score
marks, partial wear or stepped wear.
lAfter brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
Inspection Ð Lining
Check lining thickness.
Standard lining thickness:
LT26B 5.5 mm (0.217 in)
LT30A 6.1 mm (0.240 in)
Lining wear limit (A):
LT26B 1.5 mm (0.059 in)
LT30A 1.5 mm (0.059 in)
Installation
lAlways perform shoe clearance adjustment. Refer to
BR-31.
1. Fit toggle lever to brake shoe with retainer clip.
2. Apply brake grease to the contact areas shown at left.
ABR370
SBR215B
SBR095A
SBR021A
ABR371
REAR DRUM BRAKE
BR-28