Nissan Maxima 1993-1998 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



FRONT

See Figure 1


CAUTION
Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.



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Fig. Fig. 1: Exploded view of the front disc brake caliper and pads

  1. Raise and safely support vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove both guide pin bolts and brake fluid hose connector; be sure to plug the openings to prevent dirt from entering the system.
  6.  
  7. Remove the caliper assembly and pads from the vehicle.
  8.  

To install:
  1. Install the pads, shims and retainer(s).
  2.  
  3. Install the brake caliper and tighten the caliper-to-torque member pin bolts to 16-23 ft. lbs. (22-31 Nm).
  4.  
  5. Using new copper washers, install the brake line to the brake caliper and tighten the connecting bolt to 12-14 ft. lbs. (17-20 Nm).
  6.  
  7. Install the wheels and tighten the lug nuts to the proper specification.
  8.  
  9. Bleed the brake system and top off the master cylinder as necessary.
  10.  


WARNING
Make sure you pump the brakes and get a hard pedal before moving the vehicle!

REAR

See Figures 2 and 3



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Fig. Fig. 2: Exploded view of the rear caliper assembly on 1993-94 models



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Fig. Fig. 3: Rear caliper assembly found on 1995-98 models

  1. Raise and safely support the vehicle. Remove the rear wheels.
  2.  
  3. Remove the parking brake cable stay fixing bolt and the lockspring.
  4.  
  5. Remove the brake fluid hose from the caliper.
  6.  
  7. Remove the lower caliper-to-torque member pin bolt and raise the caliper.
  8.  
  9. Remove the pad retainers, the pads and the shims.
  10.  
  11. Remove the upper caliper-to-torque member pin bolt and remove the caliper.
  12.  

To install:
  1. Clean the piston end of the caliper body and the area around the pin holes. Be careful not to get oil on the rotor.
  2.  
  3. Using a pair of needle nose pliers, carefully turn the piston clockwise back into the caliper body; remove some brake fluid from the master cylinder, if necessary. Take care not to damage the piston boot.
  4.  
  5. Coat the pad contact area on the mounting support with a silicone based grease.
  6.  
  7. Install pads, shims and the pad springs.
  8.  
  9. Install the caliper body into position and tighten the caliper-to-torque member pin bolts to 16-23 ft. lbs. (22-31 Nm).
  10.  
  11. Reconnect the brake fluid hose and tighten the flare nut to 12-14 ft. lbs. (17-20 Nm).
  12.  
  13. Install the lockspring and the parking brake stay fixing bolt.
  14.  
  15. Bleed the brake system and top off the master cylinder as necessary.
  16.  
  17. Install the wheels, lower the vehicle.
  18.  


WARNING
Make sure you pump the brakes and get a hard pedal before moving the vehicle!

OVERHAUL



See Figures 4, 5, 6, 7, 8, 9, 10 and 11

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  



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Fig. Fig. 4: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Fig. 5: Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



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Fig. Fig. 6: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 7: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 8: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 9: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Fig. 10: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 11: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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