Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 45

Brakes

181

chor plate to the steering knuckle and slide the caliper
off the brake disc. Suspend the caliper clear of the
work area using wire or cord.

(3)

Suitably mark the location of the disc in

relation to the hub.

(4) Slide the disc off the hub. If the disc is

difficult to remove, install two M8 x 1.25 mm bolts in
the disc and by alternatively tightening the bolts,
remove the disc.

Do not use a hammer to remove the disc.

Installation is a reversal of the removal procedure

ensuring that the mating faces of the disc and hub are
clean and free from burrs and that the marks made on
removal are aligned.

To Inspect

(1) Inspect the machined faces of the disc for

scores, cracks, wear and signs of overheating.

(2) Using a micrometer, measure the thickness

of the disc at several positions around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

Inspect the brake discs for scoring and wear

.

(3) If the disc thickness is satisfactory but the

disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.

NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

6. REAR DISC BRAKES

Special Equipment Required:

To Check Disc Runout — Dial gauge
To Check Disc Thickness — Micrometer

TO CHECK AND RENEW BRAKE PADS

(1) Raise the rear of the vehicle and place it on

chassis stands. Remove the rear wheels.

Renew the rear brake pads if the friction material is less

than 2 mm thick.

(2) Inspect the brake pads on both sides of the

vehicle. If the friction material on one or more of the
pads is less than 2 mm thick or contaminated with
fluid or grease, renew the brake pad as a set as follows.

NOTE: If the brake pads are contaminated
trace and rectify the cause prior to installing
the new set of pads.

(3) Drain approximately two thirds of the brake

fluid from the master cylinder reservoir. This can be
done by loosening the bleeder valve on the caliper and
allowing the fluid to drain into a container. Discard
this fluid.

NOTE: Do not drain all the fluid from the
reservoir otherwise it will be necessary to
bleed the hydraulic system. The fluid is
drained from the reservoir to prevent over-
flow when the caliper piston is pushed back
into the caliper bore to facilitate pad re-
newal.

(4) Remove the guide bolts and lift the caliper

body clear of the disc.

NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Noting the installed positions, remove the

brake pads, shims and spring clips from the anchor
plate.

(6) Using a pair of long nosed pliers with the

nose located in the recesses of the piston, rotate the
piston clockwise to retract it into the cylinder body.
Align the recesses between the brake pad retaining
lugs on the caliper body. Refer to the illustration.

(7) If necessary, check the disc runout and

thickness as described under the Brake Disc heading.

(8) Ensure that the guide bolts move freely in the

caliper body and that the dust boots are in good
condition.

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Brakes

Illustration of the rear disc caliper showing the correct

piston alignment.

(9) Install the brake pads, shims and spring

clips
in the position noted on removal.

(10) Install the caliper body to its original posi-

tion. Lubricate the guide bolts with suitable grease.
Install and tighten the guide bolts to the specified
torque.

(11) Repeat the procedure on the opposite rear

brake assembly.

(12) Replenish the master cylinder reservoir with

the recommended fluid to the correct level and pump
the brake pedal several times to locate the disc pads.

(13) Install the rear wheels and lower the vehicle

to the ground.

(14) Road test the vehicle and check for correct

brake operation.

CALIPER

To Remove and Install

(1) Raise the rear of the vehicle and place it on

chassis stands. Remove the relevant rear wheel.

(2) Remove the brake hose retaining bolt from

the caliper body and plug the hose to prevent the
loss of fluid and the ingress of dirt.

Installed view of the rear brake caliper.

(3) Remove the handbrake cable bracket retain-

ing bolts and disconnect the handbrake cable from the
cam lever.

(4) Remove the bolts retaining the caliper an-

chor plate. Remove the caliper from the disc.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Tighten the caliper anchor plate bolts to the

specified torque.

(2) Install the brake hose to the caliper body

ensuring that new seal washers are installed.

NOTE: Ensure that the brake hose locating
pin is correctly installed in the caliper body.

de-

(3) Bleed the brake hydraulic system as

scribed under the Hydraulic System heading.

(4) Install the rear wheel and lower the vehicle to

the ground.

(5) Road test the vehicle and check for correct

brake operation.

Dismantled view of the rear brake caliper

Brakes

183

To Dismantle

(1) Raise the rear of the vehicle and place it on

chassis stands. Remove the relevant rear wheel.

(2) Remove the brake hose retaining bolt from

the caliper body and plug the hose to prevent the loss
of fluid and the ingress of dirt.

(3) Remove the handbrake cable bracket retain-

ing bolt and disconnect the handbrake cable from the
cam lever.

(4) Remove the guide bolts and slide the caliper

body off the pads.

(5) Using a pair of long nose pliers with the nose

located in the recesses of the piston, rotate the piston
anticlockwise to remove it from the caliper body.

(6) Remove the dust cover retaining clip and dust

cover. Discard the dust cover.

(7) Using a thin blunt probe, preferably made

from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore.

(8) Using internal snap ring pliers, remove the

snap ring from the caliper bore.

(9) Withdraw the spring cover, spring, key plate,

pushrod and link from the caliper bore. Do not mix
these components from the left and right hand sides as
they differ.

(10) Remove and discard the O ring from the

pushrod.

(11) Remove the spring, nut and washer from the

cam lever. Remove the cam lever and cam from the
caliper body.

(12) Remove the cam seal from the caliper using a

screwdriver.

(13) Clean all the caliper components in methy-

lated spirits and arrange the components in order on a
clean dry surface to aid assembly.

To Inspect

(1) Inspect the caliper bore and piston for pit-

ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.

NOTE: Slight rust spots in the caliper bore
may be removed with fine emery paper. The
piston must not be polished as the plated
surface will be damaged.

(2) Inspect the guide bolts for wear or damage

and renew as necessary.

(3) Inspect the threads of the pushrod for wear or

damage and renew as necessary.

(4) Inspect the nut inside the piston for wear,

damage and security. Renew the piston if any damage
is evident.

(5) Inspect the cam for wear, damage or pitting,

renew as necessary.

(6) Inspect the cam bearing in the caliper body

for wear, damage or pitting and renew the seal and
bearing as necessary.

(7) Inspect the guide bolt rubbers for deteriora-

tion, wear or damage. Renew as required.

To Assemble

(1) Lubricate the cam bearing with multipurpose

grease and install the seal.

(2) Install the cam and cam lever to the

caliper
body. Install the cam lever spring, washer and nut, and
tighten the nut to the specified torque.

(3) Install a new O ring to the pushrod and

install
the link, pushrod, key plate, spring and spring cover to
the caliper body. The key plate must engage the caliper
body. Secure the assembly with the snap ring.

(4) Dip a new piston seal in clean hydraulic brake

fluid. Insert the seal into the groove in the caliper bore
ensuring that the seal is correctly seated and not
twisted.

(5) Install a new dust cover to the piston prior

to
installing the piston to the caliper bore.

(6) Coat the piston and caliper bore with clean

hydraulic brake fluid and using long nose pliers rotate
the piston clockwise into the caliper bore.

(7) Locate the dust seal in the groove of the

caliper body and install the retaining clip.

(8) Lubricate the guide bolts using a suitable

grease. Install the caliper body and tighten the guide
bolts to the specified torque.

(9) Replenish the master cylinder reservoir with

the recommended fluid and bleed the brakes as
described under the Hydraulic System heading.

(10) Install the rear wheel and lower the vehicle to

the ground.

(11) Road test the vehicle and check for correct

brake operation.

BRAKE DISC

To Check Runout

(1) Raise the rear of the vehicle and support it on

chassis stands. Remove the relevant rear wheel.

(2) Mount a dial gauge stand to a suspension

component and position the dial gauge plunger
against the wheel hub. Check that the end float is less

Using a dial gauge to measure the rear disc runout.

184

Brakes

than 0.05 mm. If the wheel hub end float exceeds
Specifications, the bearing must be renewed as de-
scribed in the Rear Suspension section.

(3) Position the dial gauge plunger against the

centre of the brake disc contact area. Rotate the hub
and measure the runout. Maximum allowable runout
is 0.07 mm.

(4) If the runout exceeds the specified amount,

machine or renew the brake disc.

(5) Install the rear wheel and lower the vehicle to

the ground.

(6) Road test the vehicle and check for correct

brake operation.

To Remove and Install

(1) Raise the rear of the vehicle and support it

on chassis stands. Remove the relevant rear wheel.

(2) Remove the clip securing the brake hose to

the suspension unit and disengage the hose.

(3) Remove the bolts retaining the caliper an-

chor plate.

(4) Slide the caliper from the brake disc and

suspend the caliper clear of the work area using wire
or cord.

NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Remove the grease cap from the rear hub.
(6) Remove the split pin, nut retainer, hub nut

and washer from the stub axle.

(7) Remove the hub assembly from the stud

axle.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Tighten the rear hub to the specified torque.
(2) Install the brake caliper and tighten all the

bolts to the specified torque.

(3) Rotate the hub and check for roughness. If

the hub does not rotate smoothly, renew the hub
bearing as described in the Rear Suspension section.

(4) Install the rear wheel and lower the vehicle to

the ground.

(5) Road test the vehicle and check for correct

brake operation.

To Inspect

(1) Inspect the machined faces of the disc for

scores, cracks, wear and signs of overheating.

(2) Using a micrometer, measure the thickness

of the disc at several positions around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

(3) If the disc thickness is satisfactory but the

disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.

Inspect the machined faces of the disc for scores,

cracks, wear and signs of overheating.

NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

7. REAR DRUM BRAKES

TO REMOVE AND DISMANTLE

(1) Raise the rear of the vehicle and support it

on chassis stands. Remove the rear wheels and release
the handbrake.

(2) Remove the grease cap from the rear hub.
(3)

Remove the split pin, nut retainer, hub nut

and washer from the stub axle. Remove the brake
drum and hub assembly.

(4) Mark each brake shoe and spring to ensure

correct assembly.

(5) Rotate the star wheel until the adjuster

assembly is at its shortest length.

Installed view of the left hand side rear drum brake

components.