F BRAKES

B
SECTION
BRAKE SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 3 REMOVAL ........................................................... 14 BR
Precautions for Supplemental Restraint System INSTALLATION ................................................... 15
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- Disassembly and Assembly .................................... 15
SIONER” .................................................................. 3 DISASSEMBLY ................................................... 15 G
Precautions for Brake System .................................. 3 ASSEMBLY ......................................................... 15
PREPARATION ........................................................... 4 BRAKE BOOSTER ................................................... 16
Special Service Tool ................................................. 4 On-Vehicle Service ................................................. 16
H
Commercial Service Tools ........................................ 4 OPERATING CHECK .......................................... 16
NOISE, VIBRATION, AND HARSHNESS (NVH) AIRTIGHT CHECK .............................................. 16
TROUBLESHOOTING ................................................ 5 Removal and Installation ........................................ 17
NVH Troubleshooting Chart ..................................... 5 REMOVAL ........................................................... 17 I
BRAKE PEDAL .......................................................... 6 INSTALLATION ................................................... 18
Inspection and Adjustment ....................................... 6 VACUUM LINES ....................................................... 19
INSPECTION ........................................................ 6 Removal and Installation ........................................ 19 J
ADJUSTMENT ...................................................... 6 Inspection ............................................................... 19
Removal and Installation .......................................... 7 VISUAL INSPECTION ......................................... 19
COMPONENTS .................................................... 7 CHECK VALVE INSPECTION ............................. 20
K
REMOVAL ............................................................. 7 FRONT DISC BRAKE ............................................... 21
INSPECTION AFTER REMOVAL ......................... 8 On-vehicle Inspection ............................................. 21
INSTALLATION ..................................................... 8 PAD WEAR INSPECTION ................................... 21
BRAKE FLUID ............................................................ 9 Components ........................................................... 22 L
On-board Inspection ................................................. 9 Removal and Installation of Brake Pad .................. 23
LEVEL CHECK ..................................................... 9 REMOVAL ........................................................... 23
Drain and Refill ......................................................... 9 INSTALLATION ................................................... 23 M
Bleeding Brake System .......................................... 10 Removal and Installation of Brake Caliper and Disc
BRAKE PIPING AND HOSE .....................................11 Rotor ....................................................................... 23
Hydraulic Circuit ......................................................11 REMOVAL ........................................................... 23
Removal and Installation of Front Brake Piping and INSTALLATION ................................................... 23
Brake Hose .............................................................11 Disassembly and Assembly of Brake Caliper ......... 24
REMOVAL ............................................................11 DISASSEMBLY ................................................... 24
INSTALLATION ................................................... 12 CALIPER INSPECTION ...................................... 25
Removal and Installation of Rear Brake Piping and ASSEMBLY ......................................................... 25
Brake Hose ............................................................ 12 DISC ROTOR INSPECTION ............................... 26
REMOVAL ........................................................... 12 BRAKE BURNISHING PROCEDURE ................. 27
INSTALLATION ................................................... 12 REAR DISC BRAKE ................................................. 28
Inspection After Installation .................................... 13 On-vehicle Inspection ............................................. 28
BRAKE MASTER CYLINDER .................................. 14 PAD WEAR INSPECTION ................................... 28
On-board Inspection ............................................... 14 Components ........................................................... 28
LEAK INSPECTION ............................................ 14 Removal and Installation of Brake Pad .................. 29
Removal and Installation ........................................ 14 REMOVAL ........................................................... 29

Revision: February 2006 BR-1 2005 Xterra

 INSTALLATION .................................................... 29 SERVICE DATA AND SPECIFICATIONS (SDS) ......33
Removal and Installation of Brake Caliper and Disc General Specifications ............................................33
Rotor ....................................................................... 29 Brake Pedal ............................................................33
REMOVAL ........................................................... 29 Check Valve ............................................................33
INSTALLATION .................................................... 29 Front Disc Brake .....................................................34
Disassembly and Assembly of Brake Caliper ......... 30 Rear Disc Brake ......................................................34
DISASSEMBLY ................................................... 30
CALIPER INSPECTION ...................................... 30
ASSEMBLY ......................................................... 31
DISC ROTOR INSPECTION ............................... 31
BRAKE BURNISHING PROCEDURE ................. 32

Revision: February 2006 BR-2 2005 Xterra

 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS005G3

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING: D
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer. E
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. BR
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
G
Precautions for Brake System EFS005G4

● Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to MA-11,
"Fluids and Lubricants" . H
● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
I
● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.
● Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
● Use flare nut wrench when removing and installing brake tube. J
● Always check tightening torque when installing brake lines.
● Before working, turn ignition switch to OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery K
terminals.
● Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal L
occurs at very low mileage.
Refer to BR-27, "BRAKE BURNISHING PROCEDURE" .
WARNING:
● Clean brake pads and shoes with a waste cloth, then wipe
SBR686C M
with a dust collector.

Revision: February 2006 BR-3 2005 Xterra

 PREPARATION

PREPARATION PFP:00002

Special Service Tool EFS005G5

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
— Measuring brake pedal height
(J-46532)
Brake and clutch pedal height measure-
ment tool

LFIA0227E

Commercial Service Tools EFS005G6

Tool name Description

1. Flare nut crowfoot Removing and installing each brake pip-
2. Torque wrench ing
a: 10 mm (0.39 in) / 12 mm (0.47 in)

S-NT360

Power tool Removing nuts, bolts and screws

PBIC0190E

PBIC0191E

Revision: February 2006 BR-4 2005 Xterra

 Symptom

×: Applicable
Reference page

Noise
Possible cause and

Shake
SUSPECTED PARTS

Revision: February 2006

Shimmy, Shudder
Pads - damaged BR-21, BR-28

×
NVH Troubleshooting Chart

Pads - uneven wear BR-21, BR-28

×
Shims damaged BR-22, BR-28

×
Rotor imbalance BR-26, BR-31

×
×
Rotor damage BR-26, BR-31

×
Rotor runout BR-26, BR-31

BR-5
×
Rotor deformation BR-26, BR-31

×
Rotor deflection BR-26, BR-31

Rotor rust BR-27, BR-32

×
Rotor thickness variation BR-27, BR-32

×
PROPELLER SHAFT PR-3, "NVH Troubleshooting Chart"

×
×
FFD-6, "NVH Troubleshooting Chart" (FFD), RFD-8, "NVH Troubleshooting Chart" (RFD, C200),

×
DIFFERENTIAL
RFD-42, "NVH Troubleshooting Chart" (RFD, M226 without LD), RFD-76, "NVH Troubleshooting Chart" (RFD, M226 with LD)

FAX-4, "NVH Troubleshooting Chart" (FAX), RAX-5, "NVH Troubleshooting Chart" (RAX, C200),
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

×
×
×
DRIVESHAFT
RAX-17, "NVH Troubleshooting Chart" (RAX, M226)

SUSPENSION FSU-4, "NVH Troubleshooting Chart" (FSU), RSU-4, "NVH Troubleshooting Chart" (RSU)

×
×
×
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

TIRES AND ROAD WHEEL WT-4, "NVH Troubleshooting Chart"

×
×
×
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×
STEERING PS-5, "NVH Troubleshooting Chart"

2005 Xterra
PFP:00003

EFS005G7

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS005G8

INSPECTION
1. Inspect the brake pedal free height "H" from dash lower panel
using Tool.
Tool : — (J-46532)
2. Adjust the height referring to the following specifications.
CAUTION:
The adjustable pedal must be in the frontmost (closest to
the floor) position for pedal height measurement.

WFIA0160E

Unit: mm (in)

Free height "H" : 182.1 - 192.1 (7.17 - 7.56)

Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 : 105 - 115 (4.13 - 4.53)
lb) with engine running]
Clearance between pedal stopper and threaded end of stop lamp : 0.74 - 1.96 (0.029 - 0.077)
switch and ASCD switch "C1 " or "C2 "
Pedal play "A" : 3 - 11 (0.12 - 0.43)
ADJUSTMENT
1. Loosen the stop lamp switch and ASCD switch by turning 45° counterclockwise.
2. Loosen lock nut on the input rod, then turn input rod to adjust the
pedal to specified height. When finished adjusting, tighten lock
nut.
CAUTION:
Make sure that the screw portion of the end of input rod is
located inside the clevis.
Lock nut : 18.6 N·m (1.9 kg-m, 14 ft-lb)
3. With the pedal pulled up and held by hand, press the stop lamp
switch and the ASCD switch in until threaded ends contact pedal
arm. SBR229E

4. With the threaded ends of the stop lamp switch and ASCD
switch contacting the pedal arm, turn the switches 45° clockwise to lock in place.
CAUTION:
Make sure that the gap "C1 or C2 " between the rubber stops and switch ends are within specifica-
tion.
5. Check the pedal play.

Revision: February 2006 BR-6 2005 Xterra

 BRAKE PEDAL

CAUTION:
Make sure that the stop lamp goes off when the pedal is released. A
6. Start the engine and check the height of the brake pedal when depressing it.
Removal and Installation EFS005G9
B
COMPONENTS

BR

LFIA0232E

1. Brake pedal assembly 2. Snap pin 3. Clip L

4. Stop lamp switch 5. Pedal pad 6. Clevis pin
7. ASCD cancel switch
M
REMOVAL
WARNING:
Do not deform the brake tube.
CAUTION:
● Do not disassemble the brake pedal assembly.
● Avoid damage from dropping the brake pedal assembly during handling.
● Keep the brake pedal assembly away from water.
1. Remove the lower driver instrument panel. Refer to IP-12, "LOWER INSTRUMENT PANEL LH" .
2. Remove the stop lamp switch and ASCD switch from the pedal assembly.
3. Remove snap pin and clevis pin from the clevis of the brake booster.
4. Remove the pedal assembly.
● Temporarily install the nuts by hand to support the booster.

Revision: February 2006 BR-7 2005 Xterra

 BRAKE PEDAL

INSPECTION AFTER REMOVAL

Check brake pedal for following items.
● Crack or deformation of clevis pin stopper
● Clevis pin deformation
● Crack of any welded portion
● Brake pedal bend

SBR997

INSTALLATION
1. Installation is in the reverse order of removal.
● Check the brake pedal for smooth operation. There should be no binding or sticking when applying or
releasing the brake pedal.
● After installing the brake pedal assembly in the vehicle, be sure to adjust it. Refer to BR-6, "Inspection
and Adjustment" .

Revision: February 2006 BR-8 2005 Xterra

 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
On-board Inspection EFS005GA

LEVEL CHECK
● Check that the brake fluid level in the reservoir tank is within B
specification, between the MAX and MIN lines as shown.
● Visually check around reservoir tank for fluid leaks.
● If fluid level is excessively low, check brake system for leaks. C
● If brake warning lamp remains illuminated after the parking
brake pedal is released, check the brake system for any brake
fluid leaks.
D

LFIA0234E
E
Drain and Refill EFS005GB

CAUTION:
● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" . BR
● Do not reuse drained brake fluid.
● Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
G
when splashing it, immediately wipe off the area and wash away with water.
● Before servicing, disconnect actuator connector or battery negative cable.
1. Connect a vinyl tube to each bleed valve. H
2. Depress brake pedal, then loosen each bleed valve using a flare
nut wrench or suitable tool and gradually remove brake fluid.
I

K
SBR419C

3. Make sure there is no foreign material in reservoir tank, and refill L

with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal. M
Repeat this process a few times, then pause to add new brake
fluid to master cylinder. Continue until new brake fluid flows out.
Bleed air from brake system. Refer to BR-10, "Bleeding Brake
System" .

SBR995

Revision: February 2006 BR-9 2005 Xterra

 BRAKE FLUID

Bleeding Brake System EFS005GC

CAUTION:
While bleeding, monitor the master cylinder brake fluid level.
1. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector or battery
negative cable.
2. Connect a vinyl tube to the rear right bleed valve.
3. Fully depress brake pedal 4 to 5 times.
4. With brake pedal depressed and using a flare nut wrench or suitable tool, loosen the bleed valve to let air
out, then tighten bleed valve immediately.
5. Repeat steps 3 and 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-22, "Components" (front disc brake), BR-28,
"Components" (rear disc brake).
7. Perform steps 2 to 6 at each wheel, with master cylinder reservoir tank filled at least half way, bleed air
from the front left, rear left, and front right bleed valve, in that order.

Revision: February 2006 BR-10 2005 Xterra

 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

A
Hydraulic Circuit EFS005GD

BR

G
WFIA0345E

1. Actuator 2. Master cylinder 3. Brake booster

4. Connector H
CAUTION:
● All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.
● Make sure there is no interference with other parts when turning steering both clockwise and I
counterclockwise.
● The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble
the parts. Replace applicable part with a new one, if necessary. J
● Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
● Do not bend or twist brake hose sharply, or strongly pull it. K
● When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.
● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" . L
● Do not reuse drained brake fluid.
Removal and Installation of Front Brake Piping and Brake Hose EFS005GE
M
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench or suitable tool, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove union bolt and then remove brake hose from caliper assembly.

Revision: February 2006 BR-11 2005 Xterra

 BRAKE PIPING AND HOSE

INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt to the specified torque. Refer to
BR-11, "Hydraulic Circuit" .
NOTE:
Do not reuse copper washer.

LFIA0235E

2. Insert brake hose end through bracket, then secure it to bracket

with lock plate.
3. Install brake tube to brake hose, then tighten flare nut to the
specified torque using a flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake
System" .

LFIA0236E

Removal and Installation of Rear Brake Piping and Brake Hose EFS005GF

REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench or suitable tool, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove the brake hose from caliper assembly.
INSTALLATION
1. Install brake hose and tighten to the specified torque. Refer to
BR-11, "Hydraulic Circuit" .
NOTE:
Do not reuse copper washer.

LFIA0250E

2. Insert brake hose end through bracket, then secure it to bracket

with lock plate.
3. Install brake tube to brake hose, then tighten flare nut to the
specified torque using a flare nut wrench or suitable tool.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake
System" .

LFIA0238E

Revision: February 2006 BR-12 2005 Xterra

 BRAKE PIPING AND HOSE

Inspection After Installation EFS005GG

A
CAUTION:
If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact
with other parts, and loose connections. Replace any damaged parts. B
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately
5 seconds, check for fluid leaks from each part.
C

BR

Revision: February 2006 BR-13 2005 Xterra

 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

On-board Inspection EFS005GH

LEAK INSPECTION
● Check for leaks at master cylinder to brake booster attachment point, reservoir tank, and brake tube con-
nections.
Removal and Installation EFS005GI

Brake Master Cylinder

WFIA0411E

1. Reservoir cap 2. Strainer 3. Fluid level sensor

4. Reservoir tank 5. Grommet 6. Restriction washer
7. Master cylinder sub-assembly 8. Fluid pressure sensor 9. O-ring
10. Brake booster ⇐: Front

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.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Disconnect harness connectors for fluid level sensor and pressure sensor.
Revision: February 2006 BR-14 2005 Xterra
 BRAKE MASTER CYLINDER

3. Using a flare nut wrench or suitable tool, disconnect brake tube from master cylinder assembly.
4. Remove master cylinder assembly nuts and master cylinder assembly. A

INSTALLATION
● Installation is in the reverse order of removal. B
● Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
CAUTION:
● Refill using recommended brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
C
CANTS" .
● Do not reuse drained brake fluid.

● Adjust brake pedal. Refer to BR-6, "Inspection and Adjustment" . D

Disassembly and Assembly EFS005GJ

DISASSEMBLY
CAUTION: E
● Master cylinder cannot be disassembled.
● Remove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem- BR
bly body.
ASSEMBLY
G
CAUTION:
● Never use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
● Do not drop parts. If a part is dropped, do not use it.
H
1. Apply brake fluid or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer
to GI-46, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
CAUTION: I
Do not reuse grommet.
2. Install reservoir tank onto master cylinder assembly.
J

Revision: February 2006 BR-15 2005 Xterra

 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

On-Vehicle Service EFS005GK

OPERATING CHECK
With engine stopped, change the vacuum to the atmospheric pres-
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure the clearance between brake pedal
and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.

BRA0037D

AIRTIGHT CHECK
● Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure dis-
tance between brake pedal and floor panel gradually increases.
● Depress brake pedal while engine is running and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.
CAUTION:
Depressing pedal interval is approximately 5 seconds.

SBR365AA

Revision: February 2006 BR-16 2005 Xterra

 BRAKE BOOSTER

Removal and Installation EFS005GL

A
Brake Booster

BR

LFIA0241E

1. Brake booster hose 2. Brake booster vacuum check valve 3. Brake booster
4. Lock nut 5. Gasket 6. Spacer block

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 dur-
ing installation, dash panel may damage the threads.
● Attach the check valve in the correct direction.

Revision: February 2006 BR-17 2005 Xterra

 BRAKE BOOSTER

1. Remove actuator and electric unit. Refer to BRC-41, "Removal and Installation" (ABS), BRC-87,
"Removal and Installation" (ABLS), BRC-146, "Removal and Installation" (VDC/TCS/ABS), or BRC-216,
"Removal and Installation" (HDC/HSA/VDC/TCS/ABS).
2. Remove brake piping from brake master cylinder.
3. Remove brake master cylinder. Refer to BR-14, "Removal and Installation" .
4. Remove vacuum hose from brake booster. Refer to BR-19, "VACUUM LINES" .
5. Remove brake pedal attachment snap pin and clevis pin from inside the vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster assembly from dash panel.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length "B"
(in the figure) satisfies the specified value.
Length "B" : 150 mm (5.91 in)
2. After adjusting "B", temporarily tighten lock nut and install
booster assembly to the vehicle.
● Install a gaskets and spacer block between booster assembly
and the dash panel.
3. Connect brake pedal to clevis of input rod.
4. Install brake booster nuts.
SGIA0060E
5. Install brake piping from brake master cylinder to actuator and
electric unit. Refer to BR-11, "Hydraulic Circuit" .
6. Connect vacuum hose to brake booster.
7. Install master cylinder to booster assembly. Refer to BR-17, "Removal and Installation" .
8. Adjust the height of brake pedal. Refer to BR-6, "Inspection and Adjustment" .
9. Tighten lock nut of input rod.
10. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .

Revision: February 2006 BR-18 2005 Xterra

 VACUUM LINES

VACUUM LINES PFP:41920

A
Removal and Installation EFS005GM

Brake Booster Vacuum Hose

B

BR

WFIA0332E

1. Brake booster hose 2. Brake booster hose clip 3. Brake booster vacuum check valve
H
1. Disconnect vacuum hose from hose clip.
2. Release clamps and disconnect vacuum hose.
3. Remove check valve from brake booster. I
4. Installation is in the reverse order of removal.
CAUTION:
● Insert vacuum hose for at least 24 mm (0.94 in).
J
● Do not use lubricating oil during assembly.

M
SBR225B

Inspection EFS005GN

VISUAL INSPECTION
Check for improper assembly, damage and deterioration.

Revision: February 2006 BR-19 2005 Xterra

 VACUUM LINES

CHECK VALVE INSPECTION

Airtightness Inspection
Use a suitable vacuum pump to check. Connect to brake booster
side of check valve.
Check : Vacuum decrease should be within 1.3
valve kPa (10 mmHg, 0.39 inHg) for 15 seconds
specifi- under a vacuum of – 66.7 kPa (– 500 mmHg,
cation – 19.69 inHg)

LFIA0217E

Revision: February 2006 BR-20 2005 Xterra

 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

A
On-vehicle Inspection EFS005GO

PAD WEAR INSPECTION

● Inspect the thickness of pad through cylinder body inspection B
hole. Use a scale for inspection if necessary.
Standard thickness : 10.0 mm (0.394 in)
Repair limit thickness : 2.0 mm (0.079 in) C

BRA0010D
E

BR

Revision: February 2006 BR-21 2005 Xterra

 FRONT DISC BRAKE

Components EFS005GP

Front Disc Brake Caliper and Pads

WFIA0461E

1. Sliding pin bolt 2. Cylinder body 3. Piston seal

4. Piston 5. Piston boot 6. Sliding pin
7. Sliding pin boot 8. Torque member bolt 9. Torque member
10. Upper pad retainer 11. Outer shim 12. Inner brake pad
13. Outer brake pad 14. Lower pad retainer 15. Shim cover
16. Bleed valve 17. Cap 18. Copper washers
19. Union bolt 20. Brake hose ⇐ Front

WARNING:
Clean dust on cylinder and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.

Revision: February 2006 BR-22 2005 Xterra

 FRONT DISC BRAKE

CAUTION:
● While removing cylinder body never depress brake pedal because piston will pop out. A
● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of cylinder body. In this case, hang cylinder body with a wire so as not to stretch
brake hose. B
● Do not damage piston boot.
● Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft
pedal occurs at very low mileage. Refer to BR-27, "BRAKE BURNISHING PROCEDURE" . C
Removal and Installation of Brake Pad EFS005GQ

REMOVAL
1. Remove wheel and tire from vehicle using power tool. D
2. Remove master cylinder reservoir cap.
3. Remove lower sliding pin bolt using power tool.
E
4. Suspend cylinder body with a wire and remove pads, shim, shim covers and retainers from torque mem-
ber.
INSTALLATION BR
1. Apply Molykote AS880N grease between outer brake pad plate and shim, then attach shim and shim
cover to brake pads. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
2. Attach pad retainer to torque member, then install brake pad and G
shim assemblies.
CAUTION:
When attaching pad retainer, attach it firmly so that it is
H
flush with torque member, as shown.
3. Push pistons into cylinder body.
NOTE:
I
Using a disc brake piston tool (commercial service tool), etc.,
makes it easier to push in piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder
PFIA0273E J
reservoir tank. Watch the level of the surface of reservoir tank.
4. Remove wire then swing cylinder body down over brake pad assemblies.
5. Install lower sliding pin bolt and tighten to specification. Refer to BR-22, "Components" . K
6. Check brake for drag.
7. Inspect fluid level, then install master cylinder reservoir cap.
L
8. Install wheel and tire. Refer to WT-7, "Rotation" .
Removal and Installation of Brake Caliper and Disc Rotor EFS005GR

REMOVAL M
1. Remove wheel and tire from vehicle using power tool.
2. Drain brake fluid as necessary. Refer to BR-9, "Drain and Refill" .
NOTE:
Do not remove union bolt unless removing cylinder body from vehicle.
3. Remove union bolt as necessary and torque member bolts, then remove cylinder body from the vehicle.
NOTE:
● Position cylinder body aside using suitable wire, as necessary.

● When servicing cylinder body, remove sliding pin bolts and cylinder body from torque member.

4. Remove torque member.

5. Remove disc rotor.
INSTALLATION
CAUTION:
● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" .
● Do not reuse drained brake fluid.

Revision: February 2006 BR-23 2005 Xterra

 FRONT DISC BRAKE

1. Install disc rotor.

2. Install torque member and tighten to specification. Refer to BR-22, "Components" .
3. Install sliding pin bolts, if removed.
4. install cylinder body, then tighten sliding pin bolts to the specified
torque. Refer to BR-22, "Components" .
CAUTION:
When attaching cylinder body to the vehicle, wipe any oil
off knuckle spindle, washers and cylinder body attachment
surfaces.

LFIA0239E

5. Install brake hose to cylinder body, if removed, then tighten

union bolt to the specified torque. Refer to BR-22, "Compo-
nents" .
CAUTION:
● Do not reuse copper washers for union bolt.

● Attach brake hose to cylinder body together with union

bolt and washers.

LFIA0235E

6. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
7. Install wheel and tire. Refer to WT-7, "Rotation" .
Disassembly and Assembly of Brake Caliper EFS005GS

DISASSEMBLY
1. Remove sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque
member.

2. Remove sliding pins and sliding pin boots from torque member.
3. Place a wooden block as shown, and blow air from union bolt
mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.

BRB0032D

Revision: February 2006 BR-24 2005 Xterra

 FRONT DISC BRAKE

4. Remove piston seal from cylinder body using a suitable tool.

CAUTION: A
● Be careful not to damage cylinder inner wall.

● Do not reuse piston seal.

B

SFIA0141E

D
CALIPER INSPECTION
Cylinder Body
CAUTION: E
● Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.
● Check inside surface of cylinder for score, rust, wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.
BR
● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member G
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
H
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
ditions are observed.
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are I
stuck to sliding surface.
Sliding Pins, and Sliding Pin Boots
J
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part.
CAUTION:
K
Trailing/upper sliding pin must be replaced at each service.
ASSEMBLY
CAUTION: L
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
1. Apply clean brake fluid to new piston seal and insert seal into
groove on cylinder body. M
CAUTION:
Do not reuse piston seal.

SFIA2399E

Revision: February 2006 BR-25 2005 Xterra

 FRONT DISC BRAKE

2. Apply clean brake fluid to piston boot. Cover the piston end with
piston boot, and then install cylinder side lip on piston boot
securely into a groove on cylinder body.
CAUTION:
Do not reuse piston boot.

SFIA2432E

3. Apply brake fluid to piston, then install piston into cylinder body
and insert piston boot side lip into groove of piston as shown.
CAUTION:
Press the piston evenly to prevent damage to cylinder wall.

WFIA0211E

4. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
5. Install sliding pins and sliding pin boots to torque member.
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
6. Install cylinder body. Tighten sliding pin bolt to the specified torque. Refer to BR-22, "Components" .
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheel hub. (two or more positions.)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in)
inside the disc edge.]
Runout limit (on vehicle) : 0.05 mm (0.0020 in)
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to FAX-5, "WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole. BRA0013D

4. If runout still out of specification, turn rotor with on-car brake

lathe.

Revision: February 2006 BR-26 2005 Xterra

 FRONT DISC BRAKE

Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is A
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor.
Standard thickness : 28.0 mm (1.102 in) B
Repair limit thickness : 26.0 mm (1.024 in)
Maximum uneven wear : 0.015 mm (0.0006 in)
C
(Measured at 8 positions)

SBR020B
D

BRAKE BURNISHING PROCEDURE

Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after E
replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
BR
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
G
3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
H

Revision: February 2006 BR-27 2005 Xterra

 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

On-vehicle Inspection EFS005GT

PAD WEAR INSPECTION

● Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary.
Standard thickness : 11.0 mm (0.433 in)
Repair limit thickness : 2.0 mm (0.079 in)

BRA0010D

Components EFS005GU

Rear Disc Brake Caliper and Pads

WFIA0444E

1. Brake hose 2. Copper washer 3. Sliding pin bolt

4. Cap 5. Bleed valve 6. Cylinder body

Revision: February 2006 BR-28 2005 Xterra

 REAR DISC BRAKE

7. Sliding pin 8. Piston seal 9. Piston

10. Piston boot 11. Torque member 12. Torque member bolt A
13. Pad retainer 14. Outer shim 15. Outer brake pad
16. Inner brake pad 17. Inner shim ⇐: Front
B
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.
C
CAUTION:
● While removing cylinder body, never depress brake pedal because piston will pop out.
● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of cylinder body. In this case, hang cylinder body with a wire so as not to stretch D
brake hose.
● Do not damage piston boot.
E
● Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer to BR-32, "BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake Pad EFS005GV
BR
REMOVAL
1. Remove wheel and tire from vehicle using power tool.
2. Remove bolt from the top mount of cylinder body. G
3. Swing cylinder body open, and remove pads.
INSTALLATION
1. Push piston into cylinder body. H
NOTE:
Using a commercially available disc brake piston tool, makes it easier to push in the piston.
CAUTION: I
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
2. Install pads to cylinder body making sure they are firmly attached. J
3. Rotate cylinder body up and install top mount bolt.
4. Check brake for drag.
K
5. Install wheel and tire assembly.
Removal and Installation of Brake Caliper and Disc Rotor EFS005GW

REMOVAL L
1. Remove wheel and tire from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
3. Remove brake hose (1) and sliding pin bolts (2), then remove M
cylinder body (3).
4. Remove disc rotor.

LFIA0250E

INSTALLATION
CAUTION:
● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" .
● Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install cylinder body to the vehicle, and tighten bolts to specification. Refer to BR-28, "Components" .

Revision: February 2006 BR-29 2005 Xterra

 REAR DISC BRAKE

CAUTION:
Before installing cylinder body to the vehicle, wipe off mounting surface of cylinder body.
3. Install brake hose to cylinder body and tighten to specification. Refer to BR-28, "Components" .
CAUTION:
● Do not reuse copper washer for brake hose.

● Securely attach brake hose to protrusion on cylinder body.

4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper EFS005GX

DISASSEMBLY
1. Remove pads from cylinder body.
2. Remove sliding sleeve and boot from cylinder body.
3. Place a wooden block as shown, and blow air from brake hose
mounting hole to remove piston and piston boot.
CAUTION:
Do not get your fingers caught in piston.

BRD0041D

4. Remove piston seal from cylinder body using suitable tool.

CAUTION:
Be careful not to damage cylinder inner wall.

PFIA0269E

CALIPER INSPECTION
Cylinder Body
CAUTION:
● Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
● Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.
● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:
● Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials
are stuck to sliding surface.
● Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above conditions are observed.

Revision: February 2006 BR-30 2005 Xterra

 REAR DISC BRAKE

Sliding Pin Bolts and Sliding Pin Boots

Make sure there is no wear, damage, or cracks in sliding sleeve and sliding sleeve boots, and if there are, A
replace them.
ASSEMBLY
B
CAUTION:
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
1. Apply clean brake fluid to new piston seal and insert into groove
on cylinder body. C
CAUTION:
Do not reuse piston seal.
D

WFIA0210E
BR
2. Apply brake fluid to piston and to piston boot, then install piston
boot into piston groove.
CAUTION: G
Do not reuse piston boot.

I
WFIA0211E

J
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
K
4. Install sliding boots and sleeves to cylinder body.
DISC ROTOR INSPECTION
Visual Inspection L
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.
Runout Inspection M
1. Using wheel nuts, install disc rotor to wheel hub. (2 or more positions.)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in)
inside disk edge.]
Runout limit (on vehicle) : 0.05 mm (0.0020 in)
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cation before measuring runout. Refer to FAX-5, "On-Vehicle
Inspection and Service" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole. BRA0013D

4. If runout still out of specification, turn rotor with on-car brake

lathe.

Revision: February 2006 BR-31 2005 Xterra

 REAR DISC BRAKE

Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor.
Standard thickness : 18.0 mm (0.709 in)
Wear limit : 16.0 mm (0.630 in)
Maximum uneven wear : 0.015 mm (0.0006 in)
(measured at 8 positions)

SBR020B

BRAKE BURNISHING PROCEDURE

Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Revision: February 2006 BR-32 2005 Xterra

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications EFS005GY

Unit: mm (in)
Front brake Brake model CLZ33VB B
Rotor outer diameter × thickness 296 × 28 (11.654 × 1.102)
Pad Length × width × thickness 111.0 × 73.5 × 10.0 (4.73 × 2.894 × 0.394)
Cylinder bore diameter 46.4 (1.83)
C

Rear brake Brake model CLZ14VB

Rotor outer diameter × thickness 286 × 18.0 (11.260 × 0.709) D
Pad Length × width × thickness 83.0 × 33.0 × 11.0 (3.268 × 1.299 × 0.433)
Cylinder bore diameter 38.1 (1.50)
Control valve Valve model Electric brake force distribution E
Brake booster Booster model C215T

Diaphragm diameter 215 (8.46) BR

Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
Recommended brake fluid
CANTS" .
G
Brake Pedal EFS005GZ

Unit: mm (in)

WFIA0160E

Free height "H" 182.1 - 192.1 (7.17 - 7.56)

Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb)
105 - 115 (4.13 - 4.53)
with engine running]
Clearance between pedal stopper and threaded end of stop lamp
0.74 - 1.96 (0.029 - 0.077)
switch and ASCD switch "C1 " or “C2 ”
Pedal play "A" 3 - 11 (0.12 - 0.43)

Check Valve EFS005H1

Vacuum leakage
Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
[at vacuum of – 66.7 kPa(– 500 mmHg, – 19.69 inHg)]

Revision: February 2006 BR-33 2005 Xterra

 SERVICE DATA AND SPECIFICATIONS (SDS)

Front Disc Brake EFS005H2

Unit: mm (in)
Brake model CLZ33VB
Standard thickness (new) 10.0 (0.394)
Brake pad
Repair limit thickness 2.0 (0.079)
Standard thickness (new) 28.0 (1.102)
Repair limit thickness 26.0 (1.024)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.05 (0.0020)

Rear Disc Brake EFS005H3

Brake model CLZ14VB

Standard thickness (new) 11.0 mm (0.433 in)
Brake pad
Repair limit thickness 2.0 mm (0.079 in)
Standard thickness (new) 18.0 mm (0.709 in)
Repair limit thickness 16.0 mm (0.630 in)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015 mm (0.0006 in)
Runout limit (with it attached to the vehicle) 0.05 mm (0.0020 in)

Revision: February 2006 BR-34 2005 Xterra