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
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