Nissan Frontier. Manual - part 112

BR-28

< REMOVAL AND INSTALLATION >

BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER

Removal and Installation

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Brake Master Cylinder

CAUTION:

Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is

splashed on painted areas, wash it away with water immediately. 

NOTE:

When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-

ing.

REMOVAL

1. Remove master cylinder reservoir cap. 
2. Disconnect the harness connector from the fluid level sensor.

AWFIA0785GB

1.

Reservoir cap

2.

Strainer

3.

Fluid level sensor

4.

Reservoir tank

5.

Grommet

6.

Restriction washer

7.

Master cylinder sub-assembly

8.

O-ring

9.

Brake booster

A.

PBC (Poly Butyl Cuprysil) 
grease or silicone based 
grease

B.

Brake fluid

C.

M/T models only

R.

Rubber grease

Front

BRAKE MASTER CYLINDER

BR-29

< REMOVAL AND INSTALLATION >

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3. Disconnect the brake pipes from the master cylinder assembly.
4. Remove brake pipes from the ABS actuator and electric unit (control unit).
5. Remove the master cylinder assembly nuts and discard.

CAUTION:

Discard the nuts, do not reuse.

6. Remove the master cylinder assembly and O-ring.

CAUTION:

Do not reuse O-ring.

INSTALLATION

Installation is in the reverse order of removal.

• Apply silicone grease to the brake booster at position (A) as

shown, be sure the O-ring is in proper position when installing the

master cylinder assembly to the brake booster.

CAUTION:

Do not reuse O-ring.

• Use new master cylinder assembly nuts for installation.

CAUTION:

Do not reuse the master cylinder assembly nuts.

• Refill the brake fluid and bleed the air. Refer to 

BR-18, "Bleeding

Brake System"

.

CAUTION:

• Refill using recommended brake fluid. Refer to 

BR-18,

"Drain and Refill"

.

• Do not reuse drained brake fluid.

• Adjust the brake pedal. Refer to 

BR-16, "Inspection and Adjustment"

.

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BR-30

< REMOVAL AND INSTALLATION >

BRAKE BOOSTER

BRAKE BOOSTER

Removal and Installation

INFOID:0000000009478752

Brake Booster and Vacuum Hose

REMOVAL 

CAUTION:

• Be careful not to deform or bend brake piping while removing and installing brake booster.

• Replace clevis pin if it is damaged.

• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined during

installation, dash panel may damage the threads.

• Attach the check valve in the correct direction.
1. Remove the ABS actuator and electric unit (control unit). Refer to 

BRC-115, "Removal and Installation"

(type 1), 

BRC-236, "Removal and Installation"

 (type 2).

AWFIA0463GB

1.

Brake booster vacuum hose

2.

Brake booster vacuum check valve 3.

Brake booster

4.

Lock nut

5.

Gasket

6.

Spacer block

Front

BRAKE BOOSTER

BR-31

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2. Remove the brake master cylinder. Refer to 

BR-28, "Removal and Installation"

.

3. Remove brake booster vacuum hose from the brake booster. Refer to 

BR-32, "Removal and Installation"

.

4. Remove instrument lower panel LH. Refer to 

IP-27, "Exploded View"

.

5. Remove the brake pedal clevis pin (2) and snap pin (1) from

inside the vehicle. 

6. Remove the brake booster and brake pedal assembly nuts and discard.

CAUTION:

Discard the nuts, do not reuse.

7. Remove brake booster assembly from dash panel.

INSTALLATION

1. Loosen the lock nut (1) to adjust the input rod (2) so that length

(A) without the spacer block is within the specified value.

2. After adjusting input rod length (A), temporarily tighten the lock

nut (1) and install the booster assembly to the dash panel.

• Install gaskets and spacer block between the booster assem-

bly and the dash panel.

3. Connect the input rod using the brake pedal clevis pin (2) and

snap pin (1) from inside the vehicle. 

4. Install the brake booster using new nuts.

CAUTION:

Do not reuse the brake booster and brake pedal assembly nuts.

5. Install the brake master cylinder. Refer to 

BR-28, "Removal and Installation"

.

6. Connect the brake booster vacuum hose and check valve to the brake booster.
7. Adjust the brake pedal height. Refer to 

BR-16, "Inspection and Adjustment"

.

8. Install instrument lower panel LH. Refer to 

IP-27, "Exploded View"

.

9. Install dash side finisher. Refer to 

INT-23, "Removal and Installation"

.

10. Tighten the input rod lock nut to specification.
11. Install the ABS actuator and electric unit (control unit). Refer to 

BRC-115, "Removal and Installation"

 (type

1), 

BRC-236, "Removal and Installation"

 (type 2).

12. Refill with new brake fluid and bleed the brake system. Refer to 

BR-18, "Bleeding Brake System"

.

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Input rod (2) with lock nut (1) 
length (A) standard dimension

: Refer to 

BR-52, "Brake 

Booster"

.

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