Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION




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

See Figure 1



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Fig. Fig. 1: Exploded view of the rear disc brake components-1991-94 Sentra

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Release the parking brake.
  6.  
  7. Remove the cable guide bracket bolt and lock spring.
  8.  
  9. Disconnect the parking brake cable from the toggle lever.
  10.  
  11. Disconnect the brake hose from the caliper and plug.
  12.  
  13. Remove the slide pin bolts and lift off the caliper body.
  14.  

To install:
  1. Clean the piston end of the caliper body and the area around the pin holes.
  2.  
  3. Using the proper tool, carefully turn the piston clockwise back into the caliper body. 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 the pads, shims and the pad springs. Always use new shims.
  8.  
  9. Position the caliper body in the mounting support and tighten the pin bolts to 28-38 ft. lbs. (38-52 Nm).
  10.  
  11. Connect the brake hose and tighten the connecting bolt to 12-14 ft. lbs. (17-20 Nm).
  12.  
  13. Connect the parking brake cable to the toggle lever.
  14.  
  15. Install the cable guide bracket bolt and lock spring.
  16.  
  17. Operate the parking brake several times to properly seat the brake pads.
  18.  
  19. Properly bleed the brake system.
  20.  
  21. Install the wheels and lower the vehicle.
  22.  
  23. Verify proper brake operation before attempting to move the vehicle.
  24.  

OVERHAUL



1991-94 Vehicles

See Figures 2, 3, 4 and 5



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Fig. Fig. 2: Assembling the rear brake caliper internal components-1991-94 Sentra



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Fig. Fig. 3: Assembling the rear brake caliper external components-1991-94 Sentra



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Fig. Fig. 4: Align the key plate as shown-1991-94 Sentra



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Fig. Fig. 5: Correct positioning of the parking brake cam for installation-1991-94 Sentra

  1. Following proper procedures, remove the brake caliper from the vehicle.
  2.  
  3. Remove the caliper piston by turning counterclockwise with a suitable tool.
  4.  
  5. Remove the piston boot retainer using a suitable prybar.
  6.  
  7. Using a suitable pair of pliers, pry off the snapring and remove the spring cover, spring, key plate, pushrod and strut.
  8.  
  9. Using care not to damage the cylinder body, remove the piston seal
  10.  
  11. Remove the return spring and toggle lever.
  12.  

To assemble:
  1. Inspect all components for damage, rust, corrosion or cracks.
  2.  


WARNING
Do NOT attempt to polish the piston or cylinder body bore. These surfaces are plated and will be damaged.

  1. Clean all components in denatured alcohol and dry with compressed air.
  2.  
  3. Lubricate external moving parts with special brake system grease and internal components with brake assembly lubricant.
  4.  
  5. Insert the cam with the depression facing towards the open end of cylinder.
  6.  
  7. Apply special rubber grease to the strut and pushrod. Install the strut and pushrod.
  8.  
  9. Match the depressions in the cylinder bottom with the key plate protrusions and install the key plate.
  10.  
  11. Install the spring, spring cover. Using snapring pliers and the snapring, secure the components in place.
  12.  
  13. Lubricate and install the piston seal.
  14.  
  15. Install the piston by turning it clockwise with a suitable turning tool.
  16.  
  17. Install the toggle lever and return spring. Torque the lever nut to 27-36 ft. lbs. (37-49 Nm).
  18.  
  19. Reinstall the caliper to the vehicle.
  20.  

1995-96 Vehicles

See Figures 6, 7, 8, 9 and 10



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Fig. Fig. 6: Exploded view of rear brake components-1995-96 vehicles



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Fig. Fig. 7: Alignment of the key plate in the caliper bore-1995-96 vehicles



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Fig. Fig. 8: Install the adjuster seal as shown-1995-96 vehicles

  1. Following proper procedures, remove the brake caliper from the vehicle.
  2.  
  3. Remove the caliper piston by turning counterclockwise using a suitable tool.
  4.  
  5. Remove the piston boot retainer using a suitable prybar.
  6.  
  7. Disassemble the caliper piston as follows:
    1. Remove the snapring from the back of the piston.
    2.  
    3. Remove the adjusting nut.
    4.  

  8.  



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Fig. Fig. 9: Assembling the internal caliper components-1995-96 vehicles



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Fig. Fig. 10: Assembling the caliper piston assembly-1995-96 vehicles

  1. Using a suitable pair of pliers, remove the snapring from the caliper bore.
  2.  
  3. Remove the spring cover, spring, spring seat, key plate, pushrod and strut from the caliper bore.
  4.  
  5. Using care not to damage the cylinder body, remove the piston seal
  6.  
  7. Remove the return spring, toggle lever and cable guide from the caliper body.
  8.  

To assemble:
  1. Inspect all components for damage, rust, corrosion or cracks.
  2.  


WARNING
Do NOT attempt to polish the piston or cylinder body bore. These surfaces are plated and will be damaged.

  1. Clean all components in denatured alcohol and dry with compressed air.
  2.  
  3. Lubricate external moving parts with special brake system grease and internal components with brake assembly lubricant.
  4.  
  5. Insert the cam with the depression facing towards the open end of cylinder.
  6.  
  7. Apply special rubber grease to the strut and pushrod. Install the strut and pushrod.
  8.  
  9. Match the depressions in the cylinder bottom with the key plate protrusions. With the key plate properly positioned, secure it in place using the snapring.
  10.  
  11. Install the spring seat, spring and spring cover. Using the snapring, secure the components in place.
  12.  
  13. Assemble the piston adjuster components and install in the piston.
  14.  

Make certain that the adjuster is correctly positioned in the piston and facing the proper direction.

  1. Lubricate and install the piston seal.
  2.  
  3. Fit the piston boot to the piston and position the piston in the caliper bore.
  4.  
  5. Install the piston by turning it clockwise with a suitable tool.
  6.  
  7. Install the toggle lever, return spring and cable guide. Torque the lever nut to 18-22 ft. lbs. (25-29 Nm) and the cable guide bolt to 20-27 ft. lbs. (26-36 Nm).
  8.  
  9. Reinstall the caliper.
  10.  

 
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