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2002 2WD Nissan Xterra rotor and pad replacement procedure (Pics to follow)

REMOVAL
1) Set parking brake
2) Raise vehicle & support on jack stands. Failure to do this properly can lead to injury or death
3) Remove front wheels
4) Remove the upper and lower sliding pin bolts, sliding pins, and boots securing the caliper to the torque member.
5) Remove caliper
NOTE: Secure calipers so they do NOT hang from brake lines!!!
6) Remove pad retaining clips, shim cover (if equipped), shims, and brake pads
7) Remove two bolts securing brake guard to spindle assembly and remove guard
8) Remove grease cap
9) Remove two screws securing lock washer to wheel bearing locking nut
10) Using 2 pronged hub removal tool or center punch – remove locking nut
11) Remove the flat washer
12) Slide rotor off and remove outer bearing
13) Using suitable tool remove grease seal and inner bearing


INSTALLATION
15) Inspect bearings, bearing races, and rotors and replace if necessary
16) Clean bearings and rotor hubs
17) Repack bearings and rotor hub
18) Install inner bearing in hub and install NEW grease seal
19) Place new rotor back on spindle
20) Install outer bearing
21) Install the flat washer
22) Install the locking nut
23) Perform bearing preload procedure using suitable hub tool & torque wrench:
Tighten wheel bearing to 25 – 29 ft-lbs
Turn wheel hub several times in both directions to seat wheel bearing correctly
Again tighten wheel bearing lock nut to 25 – 29 ft-lbs
Turn back lock nut 45°. Align and install lock washer by loosening nut 15° or less using the two screws removed earlier
24) Install grease cap
25) Install brake guard to spindle assembly using two bolts previously removed and tighten to 101 to 130 ft-lbs
26) Remove master cylinder cap and place paper towels or rag around opening to catch excess brake fluid that may push out
27) Using large style C-clamp, CAREFULLY push caliper pistons back in. Use a flat piece of wood or the brake pad between the pistons and the clamp.
28) Apply anti-squeal grease to back of brake pads
29) Install brake pads, shim cover, shims, and retaining clips in caliper. Use a small amount of grease on the part of pad that slides back & forth in caliper
30) Install caliper and pads onto rotor assembly
31) Check for wear, cracks, rust and other damage on sliding pin bolts, sliding pins, and boots. Replace if any of the above conditions are observed.
32) Apply grease to sliding pins under rubber boot
33) Install sliding pins, boots, and sliding pin bolts and tighten pin bolts
to 17 – 22 ft-lbs
34) Adjust brake fluid to proper level if necessary
35) Install master cylinder cap
36) Pump brakes until hard and make sure there are no brake fluid leaks
37) Install wheels and tighten lug nuts to proper torque
38) Lower vehicle and test drive

Hub & Rotor Assembly


Rotor & Brake Guard Assembly


Exploded View Assembly
 

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Good job!! Plan on making one for the rears :)
 

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Discussion Starter #4
No problem. I'll try and put something in there before the weekend. Really busy at work right now! :)

If anyone has some pics to volunteer for the write up it would be greatly appreciated!
 

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Discussion Starter #5
Diagrams added for clarity. No actual pics yet.
 

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dezurtrat said:
No problem. I'll try and put something in there before the weekend. Really busy at work right now! :)

If anyone has some pics to volunteer for the write up it would be greatly appreciated!
If you are talking about the write up for the rears that would be awesome!! I need to get my rears done and rear brakes always scare me lol
 

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Discussion Starter #9
You can use a center punch and hammer to loosen it but to tighten it you need a special locking nut tool. I need to find the part number for you.
 

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William, call me as soon as you get this, and I will walk you through it step by step

719-640-3790
 

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Does anyone have a part number on this tool? I need to get this done (read: leaving town next week) and no one around here seems to have the slightest idea what I am talking about.
 

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Would this be any different from a 4x4 looks almost 100% the same as my 99 Isuzu Rodeo 4x4 when i did them. I used to have that tool but a sold it now i need to get another damn that link has it for less than waht i sold mine for hahahaha. I win!!!
 

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Discussion Starter #16
It's different because you don't have the hubs on the 2wd version. I think there is a write up somewhere on the 4x4. I'll try and find it.
 

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can not get the locknut off and can not find a socket to work. hope it doesn't rain to much before i can figure out a way to get this thing off. Anyone know if any of the parts stores carry that socket the only one at autozone here is way to big.
 

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Discussion Starter #19
Kyxterra, I doubt you will find one specific to the xterra. See the tool above. I basically bought one similar or that exact one and then hammered in the tabs to fit the xterra.

Hammer gently as you can crack them and break 'em off. Go to any parts store and you should be able to find one.
 
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