BRAKES

SECTION
BRAKE SYSTEM
BR B

E
CONTENTS
PRECAUTION ............................................... 3 BRAKE MASTER CYLINDER .......................... 12 BR
On Board Inspection ................................................12
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System BRAKE TUBE AND HOSE ............................... 13 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Hydraulic Circuit ......................................................13
SIONER" ................................................................... 3
FRONT BRAKE .........................................................17
Precaution for Brake System .................................... 3
FRONT BRAKE : Inspection ....................................17 H
Precaution for Procedure without Cowl Top Cover...... 4
REAR BRAKE ............................................................18
PREPARATION ............................................ 5 REAR BRAKE : Inspection ......................................18
I
PREPARATION ................................................... 5
ON-VEHICLE MAINTENANCE .................... 19
Special Service Tool ................................................. 5
Commercial Service Tool .......................................... 5 BRAKE PEDAL ................................................. 19 J
Inspection and Adjustment ......................................19
FUNCTION DIAGNOSIS ............................... 6
BRAKE FLUID .................................................. 21
NOISE, VIBRATION, AND HARSHNESS On Board Inspection ................................................21 K
(NVH) TROUBLESHOOTING ............................. 6 Drain and Refill ........................................................21
NVH Troubleshooting Chart ...................................... 6 Bleeding Brake System ...........................................21
BASIC INSPECTION .................................... 7 L
ON-VEHICLE REPAIR ................................. 23
FRONT DISC BRAKE ......................................... 7 BRAKE PEDAL ................................................. 23
BRAKE PAD ................................................................ 7 Exploded View .........................................................23 M
BRAKE PAD : Inspection .......................................... 7 Removal and Installation .........................................23

DISC ROTOR ............................................................... 7 BRAKE TUBE AND HOSE ............................... 25

N
DISC ROTOR : Inspection ........................................ 7 Hydraulic Circuit ......................................................25
Removal and Installation of Front Brake Piping
REAR DISC BRAKE ........................................... 9 and Brake Hose .......................................................29
Removal and Installation of Rear Brake Piping O
BRAKE PAD ................................................................ 9 and Brake Hose .......................................................30
BRAKE PAD : Inspection .......................................... 9 Inspection After Installation .....................................31
DISC ROTOR ............................................................... 9 P
BRAKE MASTER CYLINDER .......................... 33
DISC ROTOR : Inspection ........................................ 9
Removal and Installation .........................................33
BRAKE BOOSTER ............................................10 BRAKE BOOSTER ........................................... 35
Inspection ................................................................ 10
Removal and Installation .........................................35
VACUUM LINES .................................................11 VACUUM LINES ............................................... 38
Inspection ................................................................ 11

Revision: October 2009 BR-1 2010 Frontier

 Removal and Installation ........................................ 38 FRONT DISC BRAKE ....................................... 51
Exploded View of Brake Caliper ............................. 51
FRONT DISC BRAKE ........................................ 39 Disassembly and Assembly .................................... 51
Exploded View of Brake Pads ................................ 39
Removal and Installation of Brake Pad .................. 39 REAR DISC BRAKE .......................................... 54
Brake Burnishing .................................................... 40 Exploded View of Brake Caliper ............................. 54
Exploded View of Brake Caliper ............................. 41 Disassembly and Assembly .................................... 54
Removal and Installation of Brake Caliper and
Disc Rotor ............................................................... 41 SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 57
REAR DISC BRAKE .......................................... 44
Exploded View of Brake Pad .................................. 44 SERVICE DATA AND SPECIFICATIONS
Removal and Installation of Brake Pad .................. 44 (SDS) ................................................................. 57
Brake Burnishing .................................................... 45 General Specification .............................................. 57
Exploded View of Brake Caliper ............................. 46 Brake Pedal ............................................................ 57
Removal and Installation of Brake Caliper and Brake Booster ......................................................... 58
Disc Rotor ............................................................... 46 Check Valve ............................................................ 58
Front Disc Brake ..................................................... 58
DISASSEMBLY AND ASSEMBLY ............. 49 Rear Disc Brake ...................................................... 58
BRAKE MASTER CYLINDER ........................... 49
Disassembly and Assembly .................................... 49

Revision: October 2009 BR-2 2010 Frontier

 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000005589624

The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along C
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
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. D
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING: E
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 performed by
an authorized NISSAN/INFINITI dealer.
BR
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS H
WARNING:
When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a I
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the J
battery, and wait at least 3 minutes before performing any service.
Precaution for Brake System INFOID:0000000005272456

K
Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to MA-16, "For
North America: Fluids and Lubricants".
Do not reuse drained brake fluid.
L
Be careful not to splash brake fluid on painted areas.
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. M
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
N
negative terminal.
Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage. O
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector. SBR686C P

Revision: October 2009 BR-3 2010 Frontier

 PRECAUTIONS
< PRECAUTION >
Precaution for Procedure without Cowl Top Cover INFOID:0000000005272457

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Revision: October 2009 BR-4 2010 Frontier

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000005272458
B
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.) C
Tool name
Measuring brake pedal height
(J-46532) D
Brake and clutch pedal height measure-
ment tool

LFIA0227E

38-PFM90.5 Turning rotors

BR
( )
Pro-Cut PFM 90 On-Car Brake Lathe
G

ALFIA0092ZZ
H

Commercial Service Tool INFOID:0000000005272459

Tool name Description

1. Flare nut crowfoot Removing and installing brake piping J
2. Torque wrench a: 10 mm (0.39 in) / 12 mm (0.47 in)

S-NT360 L
Power tool Removing nuts, bolts and screws

N
PIIB1407E

Revision: October 2009 BR-5 2010 Frontier

 tom
Symp-

: Applicable
Reference page

Noise
Shake
Possible cause and
SUSPECTED PARTS

Shimmy, Shudder

Revision: October 2009

Pads - damaged BR-39 , BR-44

< FUNCTION DIAGNOSIS >

Pads - uneven wear BR-39 , BR-44

NVH Troubleshooting Chart

Shims damaged BR-39 , BR-44

Rotor imbalance BR-41 , BR-46

FUNCTION DIAGNOSIS

Rotor damage BR-41 , BR-46

Rotor runout BR-41 , BR-46

Rotor deformation BR-41 , BR-46

BR-6
Rotor deflection BR-41 , BR-46

Rotor rust BR-41 , BR-46

Rotor thickness variation BR-41 , BR-46

DLN-133, "NVH Troubleshooting Chart" (2F1310), DLN-142, "NVH Troubleshooting Chart" (2S1330),
PROPELLER SHAFT DLN-151, "NVH Troubleshooting Chart" (3S1310),

DLN-161, "NVH Troubleshooting Chart" (3S1330), DLN-171, "NVH Troubleshooting Chart" (3S1330-2BJ100)

FRONT FINAL DRIVE DLN-183, "NVH Troubleshooting Chart"

REAR FINAL DRIVE DLN-217, "NVH Troubleshooting Chart" (C200), DLN-249, "NVH Troubleshooting Chart" (M226)

DLN-273, "NVH Troubleshooting Chart" (M226 w/ ELD)
DRIVESHAFT FAX-4, "NVH Troubleshooting Chart" (FAX), RAX-5, "NVH Troubleshooting Chart" (RAX C200)

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

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

TIRES AND ROAD WHEEL WT-41, "NVH Troubleshooting Chart"

2010 Frontier
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

STEERING ST-5, "NVH Troubleshooting Chart"

INFOID:0000000005272460
 FRONT DISC BRAKE
< BASIC INSPECTION >
BASIC INSPECTION A
FRONT DISC BRAKE
BRAKE PAD
B
BRAKE PAD : Inspection INFOID:0000000005272461

PAD WEAR C
Check pad thickness from the inspection holes on cylinder body.
Check using a scale if necessary.
D
Standard thickness (new) : Refer to BR-58, "Front Disc
Brake".
Repair limit thickness : Refer to BR-58, "Front Disc E
Brake".

BR
WFIA0522E

DISC ROTOR
G
DISC ROTOR : Inspection INFOID:0000000005272462

VISUAL H
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace as necessary.
RUNOUT
I
1. Attach disc rotor to wheel hub using wheel nuts at two or more
positions.
2. Inspect runout using a dial gauge placed at 10 mm (0.39 in) J
inside the disc edge.

Runout limit : Refer to BR-58, "Front

Disc Brake". K
(with it attached to the vehicle)
NOTE: L
Before measuring, make sure that wheel bearing axial end play BRA0580D
is within the specification. Refer to FAX-5, "On-Vehicle Inspec-
tion and Service".
M
3. When runout exceeds limit value, displace mounting positions of disc rotor by one hole. And then find a
position of the minimum value for runout.
4. If runout is outside the specified value after performing the above operation, turn disc rotor using Tool.
N
Tool number : 38-PFM90.5 ( )

THICKNESS O

Revision: October 2009 BR-7 2010 Frontier

 FRONT DISC BRAKE
< BASIC INSPECTION >
Check thickness of the disc rotor using a micrometer. Replace disc
rotor if thickness is less then the repair limit thickness.

Standard thickness (new) : Refer to BR-58, "Front

Disc Brake".
Repair limit thickness : Refer to BR-58, "Front
Disc Brake".
Maximum uneven wear : Refer to BR-58, "Front
(measured at 8 positions) Disc Brake".
SBR020B

Revision: October 2009 BR-8 2010 Frontier

 REAR DISC BRAKE
< BASIC INSPECTION >
REAR DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection INFOID:0000000005272463
B
PAD WEAR
Check pad thickness from an inspection hole on cylinder body.
Check using a scale if necessary. C

Standard thickness (new) : Refer to BR-58, "Rear Disc

Brake". D
Repair limit thickness : Refer to BR-58, "Rear Disc
Brake".
E

BRA0010D
BR
DISC ROTOR
DISC ROTOR : Inspection INFOID:0000000005272464
G
VISUAL
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace as necessary.
H
RUNOUT
1. Attach disc rotor to wheel hub using wheel nuts at two or more
positions. I
2. Inspect runout using dial gauge placed at 10 mm (0.39 in) inside
disc edge as shown.
J
Runout limit : Refer to BR-58, "Rear Disc Brake".
(with it attached to the vehicle)
NOTE: K
Before measuring, make sure that wheel bearing axial end play
is within the specification. Refer to RAX-6, "Rear Axle Bearing" AWFIA0492ZZ
(C200), RAX-18, "Rear Axle Bearing" (M226). L
3. When runout exceeds limit value, displace mounting positions of disc rotor by one hole. And then find a
position of the minimum value for runout.
4. If runout is outside the specified value after performing the above operation, turn disc rotor using Tool. M

Tool number : 38-PFM90.5 ( )

THICKNESS N
Check the thickness of the disc rotor using a micrometer. Replace
disc rotor if the thickness is less then the repair limit thickness.
O
Standard thickness (new) : Refer to BR-58, "Rear
Disc Brake".
Repair limit thickness : Refer to BR-58, "Rear P
Disc Brake".
Maximum uneven wear : Refer to BR-58, "Rear
(measured at 8 positions) Disc Brake".
SFIA2284E

Revision: October 2009 BR-9 2010 Frontier

 BRAKE BOOSTER
< BASIC INSPECTION >
BRAKE BOOSTER
Inspection INFOID:0000000005272465

OPERATION
With engine stopped, change vacuum to atmospheric pressure by
depressing brake pedal several times. Then with brake pedal fully
depressed, start engine and when vacuum pressure reaches the
standard, make sure that clearance between brake pedal and floor
panel decreases.

BRA0037D

AIR TIGHT
Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change vacuum to atmospheric pressure. Make sure that distance
at intervals of 5 seconds between brake pedal and floor panel
gradually increases.

SBR365AA

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.

Revision: October 2009 BR-10 2010 Frontier

 VACUUM LINES
< BASIC INSPECTION >
VACUUM LINES
A
Inspection INFOID:0000000005272466

VISUAL INSPECTION B
Check for improper assembly, damage and deterioration. Replace as necessary.
CHECK VALVE INSPECTION
C
Airtightness Inspection
Use a suitable vacuum pump to check. Connect to brake booster
side of check valve.
D
Check valve specification : Refer to BR-58, "Check
Valve".
E

BR

LFIA0217E

Revision: October 2009 BR-11 2010 Frontier

 BRAKE MASTER CYLINDER
< BASIC INSPECTION >
BRAKE MASTER CYLINDER
On Board Inspection INFOID:0000000005272467

LEAK INSPECTION
Check for leaks at master cylinder to brake booster attachment point, reservoir tank, and brake tube connec-
tions.

Revision: October 2009 BR-12 2010 Frontier

 BRAKE TUBE AND HOSE
< BASIC INSPECTION >
BRAKE TUBE AND HOSE
A
Hydraulic Circuit INFOID:0000000005272468

Type 1 - Three Channel Hydraulic System B

BR

I
AWFIA0426ZZ

1. Actuator 2. Master cylinder 3. Brake booster J

4. Connector 5. Connector block A. Union bolt (front caliper)
9.3 Nm (0.95 kg-m, 82 in-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
B. Flare nut M12 C. Flare nut M10 D. Union bolt (rear caliper) K
18.2 Nm (1.9 kg-m, 13 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
E. Flare nut to rear hose
16.2 Nm (1.7 kg-m, 12 ft-lb)
L

Revision: October 2009 BR-13 2010 Frontier

 BRAKE TUBE AND HOSE
< BASIC INSPECTION >
Type 2 and Type 3 - Four Channel Hydraulic System

AWFIA0481ZZ

1. Actuator 2. Master cylinder 3. Brake booster

4. Connector A. Union bolt (front caliper) B. Flare nut M12
18.2 Nm (1.9 kg-m, 13 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
C. Flare nut M10 D. Union bolt (rear caliper) E. Flare nut to rear hose
13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb) 16.2 Nm (1.7 kg-m, 12 ft-lb)

Revision: October 2009 BR-14 2010 Frontier

 BRAKE TUBE AND HOSE
< BASIC INSPECTION >
Type 1
A

BR

I
WFIA0388E

1. To rear left and right disc brake 2. To front left disc brake 3. To front right disc brake
13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) J
4. From the master cylinder secondary side 5. From the master cylinder primary side 6. ABS actuator and electric unit
18.2 Nm (1.9 kg-m, 13 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb) (control unit)
7. Harness connector 8. Grommet 9. Collar K

Revision: October 2009 BR-15 2010 Frontier

 BRAKE TUBE AND HOSE
< BASIC INSPECTION >
Type 2

ALFIA0146ZZ

1. From the master cylinder secondary side 2. To rear right disc brake 3. To rear left disc brake
18.2 Nm (1.9 kg-m, 13 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb)
4. To front right disc brake 5. To front left disc brake 6. From the master cylinder primary side
13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
7. ABS actuator and electric unit (control unit) 8. Harness connector Front

Revision: October 2009 BR-16 2010 Frontier

 BRAKE TUBE AND HOSE
< BASIC INSPECTION >
Type 3
A

BR

I
ALFIA0146ZZ

1. From master cylinder secondary side 2. To rear right disc brake 3. To rear left disc brake
18.2 Nm (1.9 kg-m, 13 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) J
4. To front right disc brake 5. To front left disc brake 6. From master cylinder primary side
13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
7. ABS actuator and electric unit (control 8. Harness connector Front K
unit)

CAUTION:
All hoses and piping (tubes) must be free from excessive bending, twisting and pulling. L
Make sure there is no interference with other parts when turning steering both clockwise and coun-
terclockwise.
The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble the M
parts. Replace applicable part with a new one, if necessary.
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. N
When removing components, cover connections so that no dirt, dust, or other foreign matter gets in.
Do not reuse drained brake fluid.
After installation of the ABS actuator and electric unit (control unit), refill brake system with new O
brake fluid. Then bleed the air from the system. Refer to BR-21, "Bleeding Brake System".
FRONT BRAKE
P
FRONT BRAKE : Inspection INFOID:0000000005272469

INSPECTION AFTER REMOVAL

CAUTION:
Brake tubes and hoses are important safety parts. Always disassemble the parts and retighten their fit-
tings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is
detected.

Revision: October 2009 BR-17 2010 Frontier

 BRAKE TUBE AND HOSE
< BASIC INSPECTION >
1. Check brake lines (tubes and hoses) and connections for fluid leaks, damage, twists, deformation, contact
with other parts, and loose connections. Replace any parts as necessary. Refer to BR-13, "Hydraulic Cir-
cuit".
2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approxi-
mately 5 seconds, check each part for fluid leaks.
REAR BRAKE
REAR BRAKE : Inspection INFOID:0000000005272470

INSPECTION AFTER REMOVAL

CAUTION:
Brake tubes and hoses are important safety parts. Always disassemble the parts and retighten their fit-
tings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is
detected.
1. Check brake lines (tubes and hoses) and connections for fluid leaks, damage, twists, deformation, contact
with other parts, and loose connections. Replace any parts as necessary. Refer to BR-13, "Hydraulic Cir-
cuit".
2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approxi-
mately 5 seconds, check each part for fluid leaks.

Revision: October 2009 BR-18 2010 Frontier

 BRAKE PEDAL
< ON-VEHICLE MAINTENANCE >
ON-VEHICLE MAINTENANCE A
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000005272471
B

INSPECTION
1. Inspect the brake pedal free height (H) from the floor using Tool C
at a 90 angle to the floor as shown.

Tool number : (J-46532) D

2. Adjust the brake pedal height to specifications.

BR

AWFIA0557ZZ

J
Brake Pedal Specifications
Unit: mm (in)

M/T Refer to BR-57, "Brake Pedal".

Pedal free height (H) K
A/T Refer to BR-57, "Brake Pedal".
Pedal full stroke (S) Refer to BR-57, "Brake Pedal".
Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch (C1) or (C2) Refer to BR-57, "Brake Pedal". L
ADJUSTMENT
1. Loosen the stop lamp switch and ASCD cancel switch by turning 45 counterclockwise. M

Revision: October 2009 BR-19 2010 Frontier

 BRAKE PEDAL
< ON-VEHICLE MAINTENANCE >
2. Loosen lock nut (A) on the input rod, then turn input rod to adjust
the brake pedal to specified height. When finished adjusting,
tighten lock nut (A) to specification.

Lock nut (A) : 18.7 Nm (1.9 kg-m, 14 ft-lb)

CAUTION:
Make sure that the screw portion of the end of input rod is
located inside the clevis.
3. With the brake pedal pulled up and held by hand, press the stop
lamp switch and the ASCD cancel switch in until threaded ends
contact the brake pedal bracket.
4. With the threaded ends of the stop lamp switch and ASCD
switch contacting the pedal bracket, turn the switches 45 clock-
wise to lock in place. Check that the stop lamp switch and ASCD
cancel switch threaded end to brake pedal bracket gap (C) is
within specifications.
CAUTION:
Make sure that the gap (C) between the brake pedal bracket
and stop lamp switch and ASCD cancel switch threaded
ends are within specification.
5. Check the brake pedal for smooth operation.
CAUTION: PFIA0436E

Make sure that the stop lamp goes off when the brake pedal
is released.

Revision: October 2009 BR-20 2010 Frontier

 BRAKE FLUID
< ON-VEHICLE MAINTENANCE >
BRAKE FLUID
A
On Board Inspection INFOID:0000000005272472

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

E
LFIA0234E

Drain and Refill INFOID:0000000005272473

BR
CAUTION:
Refill with new brake fluid. Refer to MA-16, "For North America: Fluids and Lubricants".
Do not reuse drained brake fluid. G
Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
when splashing it, immediately wipe off the area and wash away with water.
Before servicing, disconnect ABS actuator and electric unit (control unit) connector or battery nega-
H
tive terminal.
1. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector or battery
negative terminal.
I
2. Connect a vinyl tube to each bleed valve.
3. Depress brake pedal, loosen each bleed valve, and gradually
remove brake fluid.
J

BRA0007D

4. Make sure there is no foreign material in reservoir tank, and refill M

with new brake fluid.
5. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
brake pedal until it stops. Tighten bleed valve. Release brake N
pedal. Repeat the process a few times, then pause to add new
brake fluid to master cylinder. Continue until the new brake fluid
flows out of the bleed valve. O
Bleed the air out of the brake hydraulic system. Refer to BR-21,
"Bleeding Brake System".
P
PFIA0403J

Bleeding Brake System INFOID:0000000005272474

CAUTION:
Refill with new brake fluid. Refer to MA-16, "For North America: Fluids and Lubricants".
Do not reuse drained brake fluid.

Revision: October 2009 BR-21 2010 Frontier

 BRAKE FLUID
< ON-VEHICLE MAINTENANCE >
Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
when splashing it, immediately wipe off the area and wash away with water.
Before servicing, disconnect ABS actuator and electric unit (control unit) connector or battery nega-
tive terminal.
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 terminal.
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-41, "Exploded View of Brake Caliper" (front disc
brake), BR-46, "Exploded View of Brake Caliper" (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: October 2009 BR-22 2010 Frontier

 BRAKE PEDAL
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR A
BRAKE PEDAL
Exploded View INFOID:0000000005272475
B

BR

AWFIA0458GB K

1. Brake pedal assembly 2. Snap pin 3. Clip

4. Stop lamp switch 5. Pedal pad 6. Clevis pin L
7. ASCD cancel switch Front

NOTE:
M
The clevis pin may be installed from either direction.
Removal and Installation INFOID:0000000005272476

N
REMOVAL
WARNING:
Do not deform the brake tube. O
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. P
1. Remove the lower instrument panel LH. Refer to IP-11, "Removal and Installation".
2. Remove the stop lamp switch and ASCD cancel switch from the pedal assembly.
3. Remove snap pin and clevis pin from the clevis of the brake booster.
4. Remove the brake pedal assembly bolt.
5. Remove the pedal assembly nuts and discard, then remove the pedal assembly.
Temporarily install the nuts by hand to support the booster.

Revision: October 2009 BR-23 2010 Frontier

 BRAKE PEDAL
< ON-VEHICLE REPAIR >
CAUTION:
Do not reuse the nuts for installation.
INSPECTION AFTER REMOVAL
Check brake pedal for following items.
Cracking or deformation of the clevis pin stopper
Clevis pin deformation
Crack of any welded portion
Brake pedal bent or deformed

SBR997

INSTALLATION
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, adjust it as necessary. Refer to BR-19, "Inspection and Adjust-
ment".
CAUTION:
Do not reuse the nuts for installation, discard and install with new lock nuts.

Revision: October 2009 BR-24 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
BRAKE TUBE AND HOSE
A
Hydraulic Circuit INFOID:0000000005272477

Type 1 - Three Channel Hydraulic System B

BR

I
AWFIA0426ZZ

1. Actuator 2. Master cylinder 3. Brake booster J

4. Connector 5. Connector block A. Union bolt (front caliper)
9.3 Nm (0.95 kg-m, 82 in-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
B. Flare nut M12 C. Flare nut M10 D. Union bolt (rear caliper) K
18.2 Nm (1.9 kg-m, 13 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
E. Flare nut to rear hose
16.2 Nm (1.7 kg-m, 12 ft-lb)
L

Revision: October 2009 BR-25 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
Type 2 and Type 3 - Four Channel Hydraulic System

AWFIA0481ZZ

1. Actuator 2. Master cylinder 3. Brake booster

4. Connector A. Union bolt (front caliper) B. Flare nut M12
18.2 Nm (1.9 kg-m, 13 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
C. Flare nut M10 D. Union bolt (rear caliper) E. Flare nut to rear hose
13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb) 16.2 Nm (1.7 kg-m, 12 ft-lb)

Revision: October 2009 BR-26 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
Type 1
A

BR

I
WFIA0388E

1. To rear left and right disc brake 2. To front left disc brake 3. To front right disc brake
13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) J
4. From the master cylinder secondary side 5. From the master cylinder primary side 6. ABS actuator and electric unit
18.2 Nm (1.9 kg-m, 13 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb) (control unit)
7. Harness connector 8. Grommet 9. Collar K

Revision: October 2009 BR-27 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
Type 2

ALFIA0146ZZ

1. From master cylinder secondary side 2. To rear right disc brake 3. To rear left disc brake
18.2 Nm (1.9 kg-m, 13 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb)
4. To front right disc brake 5. To front left disc brake 6. From master cylinder primary side
13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
7. ABS actuator and electric unit (control 8. Harness connector Front
unit)

Revision: October 2009 BR-28 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
Type 3
A

BR

I
ALFIA0146ZZ

1. From master cylinder secondary side 2. To rear right disc brake 3. To rear left disc brake
18.2 Nm (1.9 kg-m, 13 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) J
4. To front right disc brake 5. To front left disc brake 6. From master cylinder primary side
13.0 Nm (1.3 kg-m, 10 ft-lb) 13.0 Nm (1.3 kg-m, 10 ft-lb) 18.2 Nm (1.9 kg-m, 13 ft-lb)
7. ABS actuator and electric unit (control 8. Harness connector Front K
unit)

CAUTION:
All hoses and piping (tubes) must be free from excessive bending, twisting and pulling. L
Make sure there is no interference with other parts when turning steering both clockwise and coun-
terclockwise.
The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble the M
parts. Replace applicable part with a new one, if necessary.
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. N
When removing components, cover connections so that no dirt, dust, or other foreign matter gets in.
Do not reuse drained brake fluid.
After installation of the ABS actuator and electric unit (control unit), refill brake system with new O
brake fluid. Then bleed the air from the system. Refer to BR-21, "Bleeding Brake System".
Removal and Installation of Front Brake Piping and Brake Hose INFOID:0000000005272478

P
REMOVAL
1. Drain brake fluid. Refer to BR-21, "Drain and Refill".

Revision: October 2009 BR-29 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
2. Remove brake tube from brake hose, using a suitable tool.
3. Remove lock plate and brake hose from bracket.

LFIA0236E

4. Remove union bolt and copper washers, then remove brake

hose from caliper assembly.
CAUTION:
Do not reuse copper washers.

LFIA0235E

INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, then install new copper washers and union bolt.
Tighten union bolt to specified torque. Refer to BR-13, "Hydrau-
lic Circuit".
CAUTION:
Use new copper washers for installation.

SFIA1137E

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 suitable tool. Refer to BR-13, "Hydraulic
Circuit".

LFIA0236E

4. Refill brake fluid and bleed air. Refer to BR-21, "Bleeding Brake System".
Removal and Installation of Rear Brake Piping and Brake Hose INFOID:0000000005272479

REMOVAL
1. Drain brake fluid. Refer to BR-21, "Drain and Refill".

Revision: October 2009 BR-30 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
2. Remove brake tube from brake hose, using a suitable tool.
3. Remove lock plate and brake hose from bracket. A

LFIA0238E

D
4. Remove union bolt (A) and copper washers, then remove brake
hose from caliper assembly.
CAUTION:
E
Do not reuse copper washers.

BR

G
AWFIA0483ZZ

INSTALLATION
H
1. Install brake hose by aligning with the protrusion on caliper
assembly, then install new copper washers and union bolt.
Tighten union bolt to specified torque. Refer to BR-13, "Hydrau-
lic Circuit". I
CAUTION:
Do not reuse copper washers.
J

K
SFIA1137E

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

with lock plate. L
3. Install brake tube to brake hose, then tighten flare nut to the
specified torque using a suitable tool.
M

LFIA0238E
O
4. Refill brake fluid and bleed air. Refer to BR-21, "Bleeding Brake System".
Inspection After Installation INFOID:0000000005272480
P
CAUTION:
Brake pies and hoses are important safety parts. Always disassemble the parts and retighten their fit-
tings if a brake fluid leak is detected. Replace applicable part with a new one, if a damaged part is
detected.
1. Check brake pipes and hoses, and connections for fluid leaks, damage, twist, deformation, contact with
other parts, and loose connections. Replace any parts as necessary. Refer to BR-13, "Hydraulic Circuit".

Revision: October 2009 BR-31 2010 Frontier

 BRAKE TUBE AND HOSE
< ON-VEHICLE REPAIR >
2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approxi-
mately 5 seconds, check each part for fluid leaks.

Revision: October 2009 BR-32 2010 Frontier

 BRAKE MASTER CYLINDER
< ON-VEHICLE REPAIR >
BRAKE MASTER CYLINDER
A
Removal and Installation INFOID:0000000005272481

Brake Master Cylinder B

BR

L
AWFIA0462GB

1. Reservoir cap 2. Strainer 3. Fluid level sensor M

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 N
or silicone based grease
B. Brake fluid R. Rubber grease Front
O
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
P
REMOVAL
1. Drain the brake fluid. Refer to BR-21, "Drain and Refill".
2. Disconnect the harness connectors for the fluid level sensor and fluid pressure sensor.
3. Disconnect the brake pipes from the master cylinder assembly.
4. Remove brake pipes from the ABS actuator and electric unit (control unit).
5. Remove the master cylinder assembly nuts and discard.

Revision: October 2009 BR-33 2010 Frontier

 BRAKE MASTER CYLINDER
< ON-VEHICLE REPAIR >
CAUTION:
Discard the nuts, do not reuse.
6. Remove the master cylinder assembly.
7. Remove the fluid pressure sensor if required.
INSTALLATION
Installation is in the reverse order of removal.
Use new master cylinder assembly nuts for installation.
CAUTION:
Do not reuse the master cylinder assembly nuts.
Refill the brake fluid and bleed the air. Refer to BR-21, "Bleeding Brake System".
CAUTION:
Refill using recommended brake fluid. Refer to BR-21, "Drain and Refill".
Do not reuse drained brake fluid.
Adjust the brake pedal. Refer to BR-19, "Inspection and Adjustment".
Apply silicon grease to the brake booster at position (A) as shown,
be sure the O-ring is in proper position when installing the master
cylinder assembly to the brake booster.

JPFIA0013ZZ

Revision: October 2009 BR-34 2010 Frontier

 BRAKE BOOSTER
< ON-VEHICLE REPAIR >
BRAKE BOOSTER
A
Removal and Installation INFOID:0000000005272482

Brake Booster and Vacuum Hose B

BR

AWFIA0463GB
N
1. Brake booster vacuum hose 2. Brake booster vacuum check valve 3. Brake booster
4. Lock nut 5. Gasket 6. Spacer block
Front O

REMOVAL
CAUTION: P
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-71, "Removal and Installation"
(type 1), BRC-180, "Removal and Installation" (type2), BRC-300, "Removal and Installation" (type 3).

Revision: October 2009 BR-35 2010 Frontier

 BRAKE BOOSTER
< ON-VEHICLE REPAIR >
2. Remove the brake piping from the brake master cylinder.
3. Remove the brake master cylinder. Refer to BR-33, "Removal and Installation".
4. Remove brake booster vacuum hose from the brake booster. Refer to BR-38, "Removal and Installation".
5. Remove instrument panel LH. Refer to IP-17, "Exploded View".
6. Remove the brake pedal clevis pin (2) and snap pin (1) from
inside the vehicle.

JPFIA0019ZZ

7. Remove the brake booster and brake pedal assembly nuts and discard.
CAUTION:
Discard the nuts, do not reuse.
8. 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.

Input rod (2) with lock nut (1) : Refer to BR-58, "Brake
length (A) standard dimension Booster".
2. After adjusting input rod length (A), temporarily tighten the lock
nut (1) and install the booster assembly to the dash panel.
Install gaskets and spacer block between the booster assem-
bly and the dash panel.
JPFIA0238ZZ

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

JPFIA0019ZZ

4. Install the brake booster using new nuts.

CAUTION:
Do not reuse the brake booster and brake pedal assembly nuts.
5. Install the brake master cylinder. Refer to BR-33, "Removal and Installation".
6. Install the brake piping to the brake master cylinder. Refer to BR-13, "Hydraulic Circuit".
7. Connect the brake booster vacuum hose and check valve to the brake booster.
8. Adjust the brake pedal height. Refer to BR-19, "Inspection and Adjustment".
9. Install lower instrument panel LH. Refer to IP-17, "Exploded View".
10. Install dash side finisher. Refer to INT-22, "Removal and Installation".
11. Tighten the input rod lock nut to specification.

Revision: October 2009 BR-36 2010 Frontier

 BRAKE BOOSTER
< ON-VEHICLE REPAIR >
12. Install the ABS actuator and electric unit (control unit). Refer to BRC-71, "Removal and Installation" (type
1), BRC-180, "Removal and Installation" (type2), BRC-300, "Removal and Installation" (type 3). A
13. Refill with new brake fluid and bleed the air. Refer to BR-21, "Bleeding Brake System".

BR

Revision: October 2009 BR-37 2010 Frontier

 VACUUM LINES
< ON-VEHICLE REPAIR >
VACUUM LINES
Removal and Installation INFOID:0000000005272483

Brake Booster Vacuum Hose

WFIA0332E

1. Brake booster hose 2. Brake booster hose clip 3. Brake booster vacuum check valve

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.

Vacuum hose length (A) : 24 mm (0.94 in) or more

CAUTION:
Do not use lubricating oil during installation.

JPFIA0023ZZ

Revision: October 2009 BR-38 2010 Frontier

 FRONT DISC BRAKE
< ON-VEHICLE REPAIR >
FRONT DISC BRAKE
A
Exploded View of Brake Pads INFOID:0000000005272484

Front Brake Pads, Shims and Retainers B

BR

I
AWFIA0599ZZ

1. Inner shim 2. Pad return spring 3. Upper pad retainer J

4. Lower pad retainer 5. Inner brake pad 6. Outer brake pad
7. Outer shim 8. Outer shim cover M. Molykote AS-880N grease
N. Molykote 7439 grease K
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials. L
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 M
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. N
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 O
soft pedal occurs at very low mileage. Refer to BR-40, "Brake Burnishing".
Removal and Installation of Brake Pad INFOID:0000000005272485

P
REMOVAL
1. Remove the front wheel and tire. Refer to WT-46, "Rotation".
2. Remove master cylinder reservoir cap.
3. Partially drain brake fluid.
4. Remove caliper sliding pin bolts using power tool.

Revision: October 2009 BR-39 2010 Frontier

 FRONT DISC BRAKE
< ON-VEHICLE REPAIR >
5. Support the caliper body with a suitable wire to avoid pulling on the front brake hose.
6. Remove the front inner and outer brake pads, shims, shim cover, pad return spring and retainers from the
torque member.
INSTALLATION
1. Apply Molykote AS-880N grease between outer brake pad backing and shims, then attach shim and shim
cover to brake pads.
2. Apply Molykote 7439 grease as shown.

AWFIA0039ZZ

3. 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.

PFIA0273E

4. Using a suitable tool push pistons into caliper body.

CAUTION:
When pushing in piston, brake fluid returns to master cylinder 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.
5. Install pad return spring to bottom edge of the brake pads in the holes provided.
6. Install the caliper body.
7. Install the sliding pin bolts and tighten to specification. Refer to BR-41, "Exploded View of Brake Caliper".
8. Check the brakes for drag.
9. Inspect the brake fluid level, then install the master cylinder reservoir cap.
10. Install the front wheel and tire. Refer to WT-46, "Rotation".
Brake Burnishing INFOID:0000000005272486

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: October 2009 BR-40 2010 Frontier

 FRONT DISC BRAKE
< ON-VEHICLE REPAIR >
Exploded View of Brake Caliper INFOID:0000000005272487

A
Front Disc Brake Caliper

BR

AWFIA0467GB J

1. Sliding pin bolt 2. Caliper body 3. Piston seal

4. Piston 5. Piston boot 6. Sliding pin
K
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
L
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials. M
CAUTION:
While removing caliper body never depress brake pedal because piston will pop out.
Do not damage the piston boot.
If any shim is subject to serious corrosion, replace it with a new one. N
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 O
soft pedal occurs at very low mileage. Refer to BR-40, "Brake Burnishing".
Removal and Installation of Brake Caliper and Disc Rotor INFOID:0000000005272488

P
REMOVAL
1. Remove the front wheel and tire. Refer to WT-46, "Rotation".
2. Drain the brake fluid. Refer to BR-21, "Drain and Refill".
CAUTION:
Refill with new brake fluid.
Do not reuse drained brake fluid.

Revision: October 2009 BR-41 2010 Frontier

 FRONT DISC BRAKE
< ON-VEHICLE REPAIR >
3. Remove the union bolt then disconnect the brake hose and dis-
card the copper washers.
CAUTION:
Discard the copper washers, do not reuse.

LFIA0235E

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

LFIA0239E

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.

SDIA2608E

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.

SDIA2608E

2. Install torque member and tighten the torque member bolts to specification. Refer to BR-41, "Exploded
View of Brake Caliper".
3. Install the brake pads, shims, shim covers and retainers on the torque member. Refer to BR-39,
"Exploded View of Brake Pads".

Revision: October 2009 BR-42 2010 Frontier

 FRONT DISC BRAKE
< ON-VEHICLE REPAIR >
4. Install caliper body and sliding pins, then tighten the sliding pin
bolts to the specified torque. Refer to BR-41, "Exploded View of A
Brake Caliper".
CAUTION:
When installing the caliper body to the torque member,
B
wipe any oil off of the knuckle spindle, washers and caliper
body attachment surfaces.

LFIA0239E

D
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-41, "Exploded View
E
of Brake Caliper".
CAUTION:
Use new copper washers for installation.
BR

G
SFIA1137E

6. Refill with new brake fluid as necessary and bleed the air. Refer to BR-21, "Bleeding Brake System". H
CAUTION:
Refill with new brake fluid.
Do not reuse drained brake fluid.
7. Install the front wheel and tire. Refer to WT-46, "Rotation". I

Revision: October 2009 BR-43 2010 Frontier

 REAR DISC BRAKE
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
Exploded View of Brake Pad INFOID:0000000005272489

Rear Brake Pads, Shims and Retainers

AWFIA0600ZZ

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 AS-880N grease

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.
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-45, "Brake Burnishing".
Removal and Installation of Brake Pad INFOID:0000000005272490

REMOVAL
1. Remove the rear wheel and tire. Refer to WT-46, "Rotation".
2. Partially drain brake fluid.
3. Remove caliper sliding pin bolts using power tool.
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.

Revision: October 2009 BR-44 2010 Frontier

 REAR DISC BRAKE
< ON-VEHICLE REPAIR >
INSTALLATION
1. Apply Molykote AS-880N grease between the brake pad back plates and shims, then attach the shims to A
the brake pads.

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

AWFIA0039ZZ E

3. Attach pad retainer to torque member, then install brake pad and
shim assemblies.
BR
CAUTION:
When attaching pad retainer, attach it firmly so that it is
flush with torque member, as shown.
G

PFIA0273E

4. Using a suitable tool push piston into caliper body. I

CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank. J
NOTE:
Use a suitable tool to make it easier to push the piston into the caliper body.
K
5. Install the caliper body.
6. Install the sliding pin bolts and tighten to specification. Refer to BR-46, "Exploded View of Brake Caliper".
7. Check the brakes for drag. L
8. Inspect the brake fluid level, then install the master cylinder reservoir cap.
9. Install the rear wheel and tire. Refer to WT-46, "Rotation".
Brake Burnishing INFOID:0000000005272491
M

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. N
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). O
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. P
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Revision: October 2009 BR-45 2010 Frontier

 REAR DISC BRAKE
< ON-VEHICLE REPAIR >
Exploded View of Brake Caliper INFOID:0000000005272492

Rear Disc Brake Caliper

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

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-45, "Brake Burnishing".
Removal and Installation of Brake Caliper and Disc Rotor INFOID:0000000005272493

REMOVAL
1. Remove the rear wheel and tire. Refer to WT-46, "Rotation".
2. Drain the brake fluid. Refer to BR-21, "Drain and Refill".

Revision: October 2009 BR-46 2010 Frontier

 REAR DISC BRAKE
< ON-VEHICLE REPAIR >
3. Remove the union bolt (A) then disconnect the brake hose and
discard the copper washers. A
CAUTION:
Discard the copper washers, do not reuse.
B

AWFIA0483ZZ

D
4. Remove the sliding pin bolts (A) and remove the caliper body
from torque member.
E

BR

G
AWFIA0484ZZ

5. Remove the brake pads, shims and retainers from the torque member.
H
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 (A) as shown for installation. I
CAUTION:
Put matching marks on the wheel hub assembly and disc
rotor, if reusing the disc rotor.
J

AWFIA0485ZZ

INSTALLATION L
1. Install the disc rotor. If reusing the disc rotor, align the matching
marks (A) as shown for installation.
CAUTION: M
Align the matching marks on the wheel hub assembly and
disc rotor, if reusing the disc rotor.
N

O
AWFIA0485ZZ

2. Install torque member and tighten the torque member bolts to specification. Refer to BR-46, "Exploded P
View of Brake Caliper".
3. Install the brake pads, shims and retainers on the torque member. Refer to BR-44, "Exploded View of
Brake Pad".

Revision: October 2009 BR-47 2010 Frontier

 REAR DISC BRAKE
< ON-VEHICLE REPAIR >
4. Install caliper body and sliding pins, then tighten the sliding pin
bolts (A) to the specified torque. Refer to BR-46, "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.

AWFIA0484ZZ

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-13, "Hydraulic Cir-
cuit".
CAUTION:
Use new copper washers for installation.

SFIA1137E

6. Refill with new brake fluid as necessary and bleed the air. Refer to BR-21, "Bleeding Brake System".
CAUTION:
Refill with new brake fluid.
Do not reuse drained brake fluid.
7. Install the rear wheel and tire. Refer to WT-46, "Rotation".

Revision: October 2009 BR-48 2010 Frontier

 BRAKE MASTER CYLINDER
< DISASSEMBLY AND ASSEMBLY >
DISASSEMBLY AND ASSEMBLY A
BRAKE MASTER CYLINDER
Disassembly and Assembly INFOID:0000000005272494
B

Brake Master Cylinder

C

BR

AWFIA0462GB M

1. Reservoir cap 2. Strainer 3. Fluid level sensor

4. Reservoir tank 5. Grommet 6. Restriction washer
N
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
O
B. Brake fluid R. Rubber grease Front

DISASSEMBLY
CAUTION: P
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.

Revision: October 2009 BR-49 2010 Frontier

 BRAKE MASTER CYLINDER
< DISASSEMBLY AND ASSEMBLY >
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.

BRA0558D

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.

Revision: October 2009 BR-50 2010 Frontier

 FRONT DISC BRAKE
< DISASSEMBLY AND ASSEMBLY >
FRONT DISC BRAKE
A
Exploded View of Brake Caliper INFOID:0000000005272495

Front Disc Brake Caliper B

BR

AWFIA0467GB

1. Sliding pin bolt 2. Caliper body 3. Piston seal K

4. Piston 5. Piston boot 6. Sliding pin
7. Sliding pin boot 8. Torque member bolt 9. Torque member
L
10. Bleed valve 11. Cap 12. Copper washers
13. Union bolt 14. Front brake hose R. Rubber grease

WARNING: M
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. N
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. O
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. P
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-40, "Brake Burnishing".
Disassembly and Assembly INFOID:0000000005272496

DISASSEMBLY

Revision: October 2009 BR-51 2010 Frontier

 FRONT DISC BRAKE
< DISASSEMBLY AND ASSEMBLY >
1. Remove the caliper body from the torque member. Refer to BR-41, "Removal and Installation of Brake
Caliper and Disc Rotor".
2. Remove the upper sliding pin, lower sliding pin, and sliding pin boots from the torque member.
CAUTION:
Upper sliding pin must be replaced at each service.
3. Place a wooden block as shown, and then blow air from the
union bolt hole to remove the pistons and piston boots.
WARNING:
Do not get your fingers caught between the pistons and
wooden block.

BRB0032D

4. Remove the piston boots from the pistons.

CAUTION:
Do not reuse piston boot.
5. Remove piston seals from cylinder body, using a suitable tool.
CAUTION:
Be careful not to damage cylinder body inner wall.
Do not reuse piston seal.

SFIA0141E

6. Remove the bleed valve and cap.

CALIPER INSPECTION
Cylinder Body
Check the inside surface of the cylinder body for score, rust, wear, damage or foreign materials. If any of the
above conditions are observed, replace the 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.
CAUTION:
Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.
Torque Member
Check the torque member for wear, cracks, and damage. If damage or deformation is present, replace the
torque member.
Piston
Check the pistons for score, rust, wear, damage or presence of foreign materials. Replace if any of these con-
ditions are observed.
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.
Sliding Pins, and Sliding Pin Boots
Check the sliding pins and sliding pin boots for wear, damage, and cracks. If damage or deformation is
present, replace the affected part.
CAUTION:
Upper sliding pin must be replaced at each service.
ASSEMBLY

Revision: October 2009 BR-52 2010 Frontier

 FRONT DISC BRAKE
< DISASSEMBLY AND ASSEMBLY >
CAUTION:
Use NISSAN Rubber Grease when assembling. A
1. Install the bleed valve and cap.
2. Apply rubber grease to the new piston seals (1) and insert the
new piston seals (1) into the groove on the cylinder body. B
CAUTION:
Do not reuse piston seals.
C

JPFIA0032ZZ
E
3. Apply rubber grease to the new piston boots (1). Cover the pis-
ton end (2) with the piston boot (1), and then install the cylinder
side lip on the piston boot (1) securely into the groove on the cyl- BR
inder body.
CAUTION:
Do not reuse piston boot.
Press pistons in evenly and vary the pressing points to G
prevent the cylinder inner wall from being damaged.

H
JPFIA0033ZZ

4. Install the pistons (1) into the cylinder body and insert the piston I
boots (2) side lip into the piston groove as shown.
CAUTION:
Press pistons in evenly and vary the pressing points to pre-
vent the cylinder inner wall from being damaged. J

JPFIA0034ZZ
L
5. Apply rubber grease to the sliding pin boots, then install the new upper sliding pin, lower sliding pin, and
sliding pin boots on the torque member.
CAUTION: M
Upper sliding pin must be replaced at each service.
6. Install the caliper body on the torque member. Refer to BR-41, "Removal and Installation of Brake Caliper
and Disc Rotor". N

Revision: October 2009 BR-53 2010 Frontier

 REAR DISC BRAKE
< DISASSEMBLY AND ASSEMBLY >
REAR DISC BRAKE
Exploded View of Brake Caliper INFOID:0000000005272497

Rear Disc Brake Caliper

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

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-45, "Brake Burnishing".
Disassembly and Assembly INFOID:0000000005272498

DISASSEMBLY
1. Remove the caliper body from the torque member. Refer to BR-46, "Removal and Installation of Brake
Caliper and Disc Rotor".
2. Remove the sliding sleeves and boots from the torque member.

Revision: October 2009 BR-54 2010 Frontier

 REAR DISC BRAKE
< DISASSEMBLY AND ASSEMBLY >
3. Place a wooden block in the cylinder body and blow air into the
union bolt hole to remove the piston and piston boot as shown. A
WARNING:
Do not get your fingers caught between the piston and
wooden block. B

BRD0041D

D
4. Remove the piston boot from the piston.
CAUTION:
Do not reuse piston boot.
E
5. Remove piston seal from cylinder body, using a suitable tool.
CAUTION:
Be careful not to damage cylinder body inner wall.
BR

H
JPFIA0038ZZ

6. Remove the bleed valve and cap.

I
CALIPER INSPECTION
Cylinder Body
Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above condi- J
tions 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. K
CAUTION:
Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.
Torque Member L
Check the torque member for wear, cracks, and damage. If damage or deformation is present, replace the
torque member.
Piston M
Check the piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above
conditions are observed.
CAUTION:
N
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.
Sliding Pin Bolts and Sliding Pin Boots
O
Check the sliding pins and sliding pin boots for wear, damage, and cracks. If damage or deformation is
present, replace the affected part.
ASSEMBLY P
CAUTION:
Use NISSAN Rubber Grease when assembling.
1. Install the bleed valve and cap.

Revision: October 2009 BR-55 2010 Frontier

 REAR DISC BRAKE
< DISASSEMBLY AND ASSEMBLY >
2. Apply rubber grease to the new piston seal (1) and insert the
new piston seal (1) into the groove on the cylinder body.
CAUTION:
Do not reuse piston seal.

JPFIA0039ZZ

3. Apply rubber grease to the new piston boot (1). Cover the piston
end (2) with the piston boot (1), and then install the cylinder side
lip on the piston boot (1) securely into the groove on the cylinder
body.
CAUTION:
Do not reuse piston boot.
Press pistons in evenly and vary the pressing points to
prevent the cylinder inner wall from being damaged.

JPFIA0040ZZ

4. Install the piston (1) into the cylinder body and insert the piston
boot (2) side lip into the piston groove as shown.
CAUTION:
Press pistons in evenly and vary the pressing points to pre-
vent the cylinder inner wall from being damaged.

JPFIA0041ZZ

5. Apply rubber grease to the sliding pin boots, then install sliding pins and sliding pin boots on the torque
member.
6. Install the caliper body on the torque member. Refer to BR-46, "Removal and Installation of Brake Caliper
and Disc Rotor".

Revision: October 2009 BR-56 2010 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000005272499
B
Unit: mm (in)

Engine Type QR25DE VQ40DE C

Front brake Brake model CLZ33VA
Rotor outer diameter thickness 283 28 (11.142 1.102) 296 28 (11.654 1.102)
Pad Length width thickness 140 49 10 (5.51 1.93 0.39) D
Cylinder bore diameter (each) 46.4 (1.83)
Rear brake Brake model CLZ14VA
E
Rotor outer diameter thickness 286 18 (11.260 0.709)
Pad length width thickness 87.6 35.5 11.0 (3.449 1.398 0.433)
Cylinder bore diameter 38.1 (1.50) BR
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
G
Diaphragm diameter 215 (8.465)

Recommended brake fluid Refer to MA-16, "For North America: Fluids and Lubricants".
H
Brake Pedal INFOID:0000000005272500

Unit: mm (in)
I

AWFIA0557ZZ
P
M/T 174.7 (6.88)
Pedal free height (H)
A/T 182.1 (7.17)
Pedal full stroke (S) 153 (6.02)
Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch (C1) or (C2) 0.74 - 1.96 (0.029 - 0.077)

Revision: October 2009 BR-57 2010 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Brake Booster INFOID:0000000005272501

Unit: mm (in)

JPFIA0238ZZ

Input rod (2) with lock nut (1) length (A) standard dimension 149 0.5 (5.87 0.02)

Check Valve INFOID:0000000005272502

Vacuum leakage
Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
[at vacuum of -66.7 kPa(-500 mmHg, -19.69 inHg)]

Front Disc Brake INFOID:0000000005272503

Unit: mm (in)
Engine type QR25DE / VQ40DE
Brake model CLZ33VA
Standard thickness (new) 10.0 (0.394)
Brake pad
Repair limit thickness 2.0 (0.079)
Standard thickness (new) 28.0 (1.102)
Repair limit thickness 26.0 (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 INFOID:0000000005272504

Unit: mm (in)
Engine type QR25DE / VQ40DE
Brake model CLZ14VA
Standard thickness (new) 11.0 (0.433)
Brake pad
Repair limit thickness 2.0 (0.079)
Standard thickness (new) 18.0 (0.709)
Repair limit thickness 16.0 (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: October 2009 BR-58 2010 Frontier