Nissan Maxima Service and Repair Manual: Front disc brake

Exploded View of Brake Pads

1. Inner shim cover
2. Inner shim
3. Inner pad
4. Outer pad
5. Outer shim
6. Outer shim cover
7. Anti-rattle clips
8. Pad retainers
1. Molykote AS-880N grease
2.  Molykote 7439 grease

Removal and Installation of Brake Pads

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

CAUTION:

• While removing brake pads, do not 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 assembly. For brake pad removal, hang cylinder body with a wire so as not to stretch brake hose.
• Do not damage 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 and pads free from grease and brake fluid.
• Burnish the brake pads and disc rotor contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-31, "Brake Burnishing Procedure".

REMOVAL

1. Remove front wheel and tire using power tool. Refer to WT-60, "Adjustment".
2. Partially drain brake fluid from master cylinder.
3. Remove the upper and lower sliding pin bolts.
   NOTE: Note the sliding pin orientation during removal. The lower sliding pin contains a bushing.
4. Remove the brake caliper from the torque member. Leaving the brake hose attached, reposition the brake caliper aside with wire.
5. Remove anti-rattle clips, pads, shims, and shim covers from torque member.

INSTALLATION

1. Apply Molykote AS-880N grease or equivalent between the inner and outer shims and the back of the brake pads.
2. Install the inner and outer shims and shim covers to the inner pad and outer pad.
   CAUTION: Do not get grease on the inner and outer pad friction surfaces.
3. Apply Molykote 7439 grease (A) or equivalent to the pad retainer and attach the pad retainer to the torque member.
4. Install the assembled inner and outer shims, shim covers, pads and anti-rattle clips to the torque member.
   CAUTION: Do not get grease on the inner and outer pad or rotor friction surfaces.
5. Press piston into cylinder body using suitable tool, then install the cylinder body on the torque member.
   CAUTION: When replacing pads with new set, check the brake fluid level in the reservoir tank because brake fluid returns to the master cylinder reservoir tank when pressing in the piston.
6. Install the upper and lower sliding pin bolts (2) and tighten it to the specified torque.

• Union bolt (1)

7. Check front disc brakes for drag.
8. Install the front wheel and tire. Refer to WT-60, "Adjustment".
9. Check brake fluid level and refill as necessary. Refer to BR-16, "Inspection".

Brake Burnishing Procedure

Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.

CAUTION:

• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted.
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

Exploded View of Brake Caliper

1. Union bolt
2. Copper sealing washer
3. Brake hose
4. Cap
5. Bleed valve
6. Sliding pin bolt
7. Piston seal
8. Piston
9. Piston boot
10. Cylinder body
11. Upper sliding pin
12. Lower sliding pin bolt
13. Torque member bolt
14. Washer
15. Sliding pin boot
16. Bushing
17. Torque member
1. Rubber grease
2.  Brake fluid

Removal and Installation of Brake Caliper and Rotor

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

CAUTION:

• When removing and installing the cylinder body, do not depress the brake pedal because the piston will pop out.
• Do not damage the piston boot.
• Keep the brake rotor free from grease and brake fluid.
• Refill the brake reservoir with new brake fluid only.
• Do not reuse the drained brake fluid.

NOTE: When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1. Remove front wheel and tire using power tool. Refer to WT-60, "Adjustment".
2. Secure the disc rotor using a wheel nut.
3. Remove the reservoir cap.

4. Remove the union bolt (1) and disconnect the brake hose from the caliper assembly. Discard the copper sealing washers.
   CAUTION: Do not reuse copper sealing washers.
5. Remove the upper and lower sliding pin bolts.
   NOTE: Note the sliding pin orientation during removal. The lower sliding pin contains a bushing.
6. Remove the brake caliper.
7. Remove the torque member bolts (2), and the torque member.
   CAUTION: Do not drop the brake pads.
8. Remove the disc rotor. If reusing the disc rotor, apply a matching mark as shown for installation.
   CAUTION: Put matching marks on wheel hub assembly and disc rotor, if reusing the disc rotor.

INSTALLATION

1. Install the disc rotor. If reusing the disc rotor, align the matching mark on the disc rotor and wheel hub assembly for installation as shown.

CAUTION: Align the matching marks on wheel hub assembly and disc rotor, if reusing the disc rotor.

2. Install the brake caliper assembly, and tighten the torque member bolts to the specified torque.
   CAUTION: Do not allow oil or any moisture on all contact surfaces between steering knuckle and caliper assembly, bolts, and washer.
3. Install the brake hose with two new copper sealing washers (1), using the L-shaped pin for alignment as shown, then tighten the union bolt (A) to the specified torque.
   CAUTION: Do not reuse copper sealing washers.
4. Refill the brake hydraulic system with new brake fluid and bleed air. Refer to BR-16, "Bleeding Brake System".
5. Check the front disc brakes for drag.
6. Install the reservoir cap.
7. Install the front wheel and tire. Refer to WT-60, "Adjustment".