Quest 1995-1996

Brake Disc (Rotor)

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Inspection



Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

If there are light surface irregularities on the rotor, both sides of the rotor may be sanded with fine emery cloth. If there are deep scratches or scoring, the rotor should be machined (turned).

Rotor thickness should be measured any time a brake inspection is done. Rotor thickness can be measured using a brake rotor micrometer or Vernier caliper. Measure the rotor thickness in several places around the rotor. The minimum thickness is marked on the outboard side of the rotor. The thickness at which the rotor becomes unsafe is called the discard thickness. The discard thickness is 0.945 inch (24mm). To find the minimum thickness to which the rotor can be machined, add 0.030 inch (0.762mm) to the discard limit marked on the rotor. This 0.974 inch (24.762mm) machining limit allows for rotor wear after the rotor has been resurfaced and returned to service.

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Fig. Check brake rotor thickness in several places around the rotor

The run-out of the brake rotor should be checked if vibration in the steering wheel or front of the vehicle during braking occurs. Remove the rotor and thoroughly clean the hub and rotor-to-hub mounting surface on the back of the rotor. Install the rotor onto the wheel hub and secure it with at least two lug nuts. Mount a dial indicator to a suspension member and zero the indicator stylus on the face of the rotor. Rotate the rotor 360 degrees by hand and record the run-out. The maximum allowable run-out is 0.0028 inch (0.07mm). If run-out exceeds specifications, the rotor may need to be machined, or replaced if machining will bring the thickness below 0.030 inch (0.762mm) above the discard limit.

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Fig. Dial indicator mounting to check brake rotor run-out

Removal & Installation



Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

  1. Loosen the lug nuts on the front wheels.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle securely on jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Using a Torx ® T-40 bit, remove the two caliper bolts.
  8.  
  9. Lift the caliper and brake pad assembly from the rotor using a rotating motion.
  10.  
  11. Suspend the caliper from the strut with wire. Do not allow the caliper to hang from the brake hose.
  12.  
  13. Remove the rotor by pulling it off of the wheel hub bolts. If the rotor does not come off easily, apply penetrating oil on the rotor and wheel hub mating surfaces. Strike the rotor between the wheel studs with a plastic hammer.

    Click image to see an enlarged view

    Fig. Removing the rotor

  14.  

To install:

  1. If the rotor is being replaced with a new part, clean any protective coating off of the rotor with carburetor cleaner. If the original rotor is being installed, clean and inspect it for thickness and run-out.
  2.  
  3. Install the rotor on the hub.
  4.  
  5. Install the caliper.
  6.  
  7. Install the wheel and tighten the lug nuts to 72 - 87 ft. lbs. (98 - 118 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Pump the brake pedal several times prior to moving the vehicle to position the brake pads to the rotor.
  12.  
  13. Refill the master cylinder reservoir as necessary, using only new DOT 3 or equivalent brake fluid.
  14.  
  15. Road test the vehicle and check the brake system for proper operation.
  16.  

 
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