Nissan Z - ZX 1970-1988 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



1970-78 Models

See Figures 1 and 2

  1. Refer to the Disc Brake Pad removal and installation procedures in this section, and remove the brake pads.
  2.  
  3. Disconnect the brake line, then remove the caliper bolts and the caliper assembly.
  4.  
  5. To install, reposition the caliper and tighten the caliper bolts to 53-72 ft. lbs. (73-99 Nm).
  6.  
  7. Refer to the Disc Brake Pad removal and installation procedures in this section, and install the brake pads.
  8.  
  9. Reconnect the brake line and bleed the system.
  10.  



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Fig. Fig. 1: Disassembled 1970-78 front caliper



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Fig. Fig. 2: Brake line (1) and caliper retaining bolts (2)

When bleeding the brake system, it may be only necessary to bleed the line which was disconnected.

1979-88 Models
  1. Raise and support the front of the vehicle on jackstands. Remove the wheel.
  2.  
  3. Using a flare nut wrench, disconnect and plug the brake hose.
  4.  
  5. The caliper is retained to the knuckle spindle by two bolts. Remove the bolts and the caliper assembly.
  6.  
  7. To install, place the caliper in position on the spindle without the pads or pad retainer. Install the upper caliper bolt loosely. Install the pads and pad retainer. Swing the caliper down and install the lower bolt. Tighten the caliper-to-torque member bolts to 53-72 ft. lbs. (73-99 Nm) and the brake hose to 11-13 ft. lbs. (15-18 Nm). Bleed the brakes.
  8.  

OVERHAUL



1970-78 Models

See Figures 1 and 2

The caliper halves must not be separated. If brake fluid leaks from the bridge seal, replace the caliper assembly.

  1. Clean the caliper assembly of all accumulated mud and dust.
  2.  
  3. Remove the caliper from the steering knuckle.
  4.  
  5. Remove the retaining rings and the dust covers.
  6.  
  7. Hold one piston with a finger so that it will not come out and gradually apply air pressure to the brake line fitting. This should cause the other piston to come out but if the piston you are holding begins moving before the other, switch your finger over and remove the more movable one first.
  8.  
  9. Carefully push the other piston out.
  10.  
  11. With a finger, carefully remove both piston seals.
  12.  
  13. Thoroughly clean all parts in brake fluid.
  14.  
  15. Inspect, as follows:
    1. Check cylinder walls for damage or excessive wear. Light rust should be removed with fine emery paper. If the wall is heavily rusted, replace the caliper assembly.
    2.  
    3. Inspect the pad, as described in this section.
    4.  
    5. Inspect the piston for uneven wear, damage or rust. Replace the piston if there is rust, as it is chrome plated and cannot be cleaned.
    6.  
    7. Replace piston seals and dust covers.
    8.  

  16.  
  17. Coat the piston seal with brake fluid and carefully install the piston seal.
  18.  
  19. Install the dust seal onto the piston. Coat the piston with brake fluid. Install the piston and seal assembly, then the retaining ring.
  20.  
  21. Repeat Steps 9 and 10 for the other piston.
  22.  

1979-88 Models

See Figures 3, 4, 5, 6, 7, 8 and 9

  1. Raise and support the front of the vehicle on jackstands. Remove the wheels.
  2.  
  3. Remove the brake hose, then plug the caliper and hose to prevent leakage.
  4.  
  5. Remove the two mounting bolts and the caliper from the spindle.
  6.  
  7. Remove the two pin bolts and separate the caliper from the torque member.
  8.  
  9. Remove the pad retainers and the pads.
  10.  
  11. Gradually apply compressed air to the fluid inlet, then remove the pistons and the dust seals. Remove the piston seals.
  12.  

On the CL28VE (dual piston type), use a wooden block so that the two pistons come out evenly.

  1. Check the caliper bore for scoring, wear, corrosion and/or etc. Minor damage can be cleaned up with crocus cloth but deep pits or wear warrant caliper replacement. The piston is plated and must not be polished.
  2.  
  3. Install the piston seals.
  4.  
  5. Lubricate the piston, dust seals and caliper bore with clean brake fluid. Install the dust seal to the piston, then install the other lip of the seal into the caliper bore groove. Install the piston.
  6.  
  7. Apply a thin coat of grease to the torque member (where it contacts the pads), the pin bushings and the pins.
  8.  
  9. Install the pin bolts, torquing them to 16-23 ft. lbs. (22-32 Nm).
  10.  
  11. Install the caliper.
  12.  



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Fig. Fig. 3: Use compressed air to force the piston out of the bore



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Fig. Fig. 4: Removing the piston from the cylinder



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Fig. Fig. 5: Remove the dust shield from the caliper



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Fig. Fig. 6: Use a pick tool to remove the seal from inside the cylinder bore



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Fig. Fig. 7: Exploded view of 1979-83 front brake caliper



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Fig. Fig. 8: Exploded view of 1984-88 front caliper (except 1987-88 turbo models)



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Fig. Fig. 9: Exploded view of two-piston front caliper assembly-1987-88 turbo models

 
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