F BRAKES

B
SECTION
BRAKE SYSTEM C

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

Revision: January 2005 BR-1 2004 Pathfinder Armada

 REMOVAL ........................................................... 26 SERVICE DATA AND SPECIFICATIONS (SDS) ......30
INSTALLATION .................................................... 26 General Specifications ............................................30
Removal and Installation of Brake Caliper Assembly Brake Pedal ............................................................30
and Disc Rotor ........................................................ 26 Brake Booster .........................................................30
REMOVAL ........................................................... 26 Check Valve ............................................................30
INSTALLATION .................................................... 26 Front Disc Brake .....................................................30
Disassembly and Assembly of Brake Caliper Rear Disc Brake ......................................................31
Assembly ................................................................ 27
DISASSEMBLY ................................................... 27
CALIPER INSPECTION ...................................... 27
ASSEMBLY ......................................................... 27
DISC ROTOR INSPECTION ............................... 28
BRAKE BURNISHING PROCEDURE ................. 29

Revision: January 2005 BR-2 2004 Pathfinder Armada

 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS0037V

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 EFS0037W

● Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" for recommended brake fluid.
H
● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. I
● 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.
● Always check tightening torque when installing brake lines. J
● Before working, turn ignition switch to OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery
terminals. K
● Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage. Refer to BR-24, "BRAKE BURNISH- L
ING PROCEDURE" .
WARNING: SBR686C
● Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector. M

Revision: January 2005 BR-3 2004 Pathfinder Armada

 PREPARATION

PREPARATION PFP:00002

Special Service Tool EFS005TW

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 EFS005TX

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: January 2005 BR-4 2004 Pathfinder Armada

 Symptom

×: Applicable
Reference page

Possible cause and

Noise
Shake
SUSPECTED PARTS

Revision: January 2005

Shimmy, Shudder
×
Pads - damaged BR-20, BR-25
NVH Troubleshooting Chart

Pads - uneven wear BR-20, BR-25

×
Shims damaged BR-20, BR-25

×
×
Rotor imbalance BR-24, BR-28

Rotor damage BR-24, BR-28

BR-5
×
Rotor runout BR-24, BR-28

Rotor deformation BR-24, BR-28

×
Rotor deflection BR-24, BR-28

×
×
Rotor rust BR-24, BR-29

Rotor thickness variation BR-24, BR-29

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

DIFFERENTIAL RFD-5, "NVH Troubleshooting Chart"

×
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

DRIVESHAFT PR-3, "NVH Troubleshooting Chart"

×
×
×

×
×
×
SUSPENSION FSU-4, "NVH Troubleshooting Chart" (FSU), RSU-5, "NVH Troubleshooting Chart" (RSU)
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

TIRES AND ROAD WHEEL WT-3, "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"

2004 Pathfinder Armada

PFP:00003

EFS0037Y

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS003DJ

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

WFIA0160E

Brake Pedal Specifications

Free height "H" : 182.3 - 192.3 mm (7.18 - 7.57 in)
Depressed pedal height "D" [under a force of 490 N (50 kg, 110 lb) with engine
: More than 90.3 mm (3.55 in)
running]
Clearance between pedal stopper and threaded end of stop lamp switch and
: 0.74 - 1.96 mm (0.029 - 0.077 in)
ASCD switch "C1 " or “C2 ”
Pedal play "A" : 3 - 11 mm (0.12 - 0.43 in)

ADJUSTMENT
1. Loosen the stop lamp switch and ASCD switch by turning 45° counterclockwise.

Revision: January 2005 BR-6 2004 Pathfinder Armada

 BRAKE PEDAL

2. Loosen lock nut on the input rod, then turn input rod to adjust the
pedal to specified height. When finished adjusting, tighten lock A
nut.
CAUTION:
Make sure that the screw portion of the end of input rod is B
located inside the clevis.
Lock nut : 18.5 N·m (1.9 kg-m, 14 ft-lb)
C
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.
4. With the threaded ends of the stop lamp switch and ASCD D
switch contacting the pedal arm, turn the switches 45° clockwise
to lock in place.
CAUTION: E
Make sure that the gap (C) between the rubber stops and
switch ends are within specification.
5. Check the pedal play. BR
CAUTION:
Make sure that the stop lamp goes off when the pedal is
released. G
6. Start the engine and check the height of the brake pedal when PFIA0436E

depressing it.
Removal and Installation EFS003DK
H

WFIA0232E

Revision: January 2005 BR-7 2004 Pathfinder Armada

 BRAKE PEDAL

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

4. Stop lamp switch 5. Pedal pad 6. Clevis pin
7. ASCD cancel switch

REMOVAL
WARNING:
Do not deform the brake tube.
CAUTION:
● Before removal and installation the accelerator and brake pedals must be in the forward most
position (closest to the floor). This is to align the base position of the accelerator and brake ped-
als.
● Do not disassemble the brake pedal adjusting mechanism.
● 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-10, "Removal and Installation" .
2. Remove the stop lamp switch and ASCD switch from the pedal assembly.
3. Disconnect the adjustable brake pedal cable from the adjustable
pedal electric motor.
● Unlock (1) then pull (2) the adjustable brake pedal cable to
disconnect it from the adjustable pedal electric motor as
shown.
4. Remove snap pin and clevis pin from the clevis of brake booster.
5. Remove mounting nuts and the pedal assembly.
● Temporarily install nuts by hand to support booster.

CAUTION:
● Before removal and installation the accelerator and brake LBIA0374E
pedals must be in the forwardmost position (closest to
the floor). This is to align the base position of the accelerator and brake pedals.
● Do not disassemble the brake pedal adjusting mechanism.

● Avoid damage from dropping the brake pedal assembly during handling.

● Keep the brake pedal assembly away from water.

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.
● Check the brake pedal adjustable feature for smooth operation. There should be no binding or sticking
when adjusting the brake pedal forward or backward.
● After installing the brake pedal assembly in the vehicle, be sure to adjust it. Refer to BR-6, "Inspection and
Adjustment" .

Revision: January 2005 BR-8 2004 Pathfinder Armada

 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
On-board Inspection EFS00381

LEVEL CHECK
● Make sure the fluid level in reservoir tank is within the standard B
(between MAX and MIN lines).
● 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 parking lever is
released, check brake system for fluid leakage.
D

WFIA0173E
E
Drain and Refill EFS00382

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, loosen each bleed valve, 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: January 2005 BR-9 2004 Pathfinder Armada

 BRAKE FLUID

Bleeding Brake System EFS00383

CAUTION:
While bleeding, pay attention to master cylinder 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, loosen bleed valve to let the air out, and then tighten it immediately.
5. Repeat steps 3 and 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-20, "Components" (front disc brake), BR-25,
"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: January 2005 BR-10 2004 Pathfinder Armada

 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

A
Hydraulic Circuit EFS00384

BR

G
WFIA0278E

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 EFS00385
M
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, 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: January 2005 BR-11 2004 Pathfinder Armada

 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.
NOTE:
Do not reuse copper washer.

LFIA0214E

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" .

LFIA0213E

Removal and Installation of Rear Brake Piping and Brake Hose EFS00386

REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, 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.
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt to the specified torque.
NOTE:
Do not reuse copper washer.

LFIA0212E

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" .

LFIA0213E

Revision: January 2005 BR-12 2004 Pathfinder Armada

 BRAKE PIPING AND HOSE

Inspection After Installation EFS00387

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 damage 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 leakage from each part.
C

BR

Revision: January 2005 BR-13 2004 Pathfinder Armada

 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

On-board Inspection EFS00388

LEAK INSPECTION
● Check for leaks at master cylinder to brake booster attachment point, reservoir tank, and brake tube con-
nections.
Removal and Installation EFS00389

WFIA0378E

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

4. Master cylinder sub-assembly 5. Front pressure sensor 6. Rear pressure sensor
7. Reservoir tank 8. Seal

CAUTION:
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.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Disconnect harness connectors for fluid level sensor and pressure sensors.
3. Using a flare nut wrench, disconnect brake tube from master cylinder assembly.
4. Remove master cylinder assembly mounting nuts and master cylinder assembly.

Revision: January 2005 BR-14 2004 Pathfinder Armada

 BRAKE MASTER CYLINDER

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

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

Disassembly and Assembly EFS0038B

DISASSEMBLY D
CAUTION:
● Master cylinder cannot be disassembled.
● Remove reservoir tank only when absolutely necessary. E
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.
ASSEMBLY BR
CAUTION:
● Never use mineral oil such as kerosene, gasoline during the cleaning and assembly process.
● Do not drop parts. If a part is dropped, do not use it. G
1. Apply brake fluid or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer
to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
CAUTION: H
Do not reuse grommet.
2. Install reservoir tank onto master cylinder assembly.
I

Revision: January 2005 BR-15 2004 Pathfinder Armada

 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

On-Vehicle Service EFS0038C

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: January 2005 BR-16 2004 Pathfinder Armada

 BRAKE BOOSTER

Removal and Installation EFS0038D

BR

WFIA0233E

1. Reservoir tank 2. Master cylinder 3. Gasket G

4. Brake pedal 5. Lock nut 6. Spacer block
7. Brake booster 8. Active booster 9. Delta stroke sensor
H
REMOVAL
CAUTION:
● Be careful not to deform or bend brake piping while removing and installing brake booster. I
● 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. J
● Attach the check valve in the correct direction.
1. Remove engine room cover using power tool. Refer to EM-11, "Removal and Installation" .
2. Remove engine air duct assembly. Refer to EM-14, "Removal and Installation" . K
3. Remove brake piping from brake master cylinder.
4. Remove brake master cylinder. Refer to BR-14, "Removal and Installation" .
L
5. Remove vacuum hose from brake booster. Refer to BR-19, "VACUUM LINES" .
6. Disconnect active boost and delta stroke sensor harness connectors from brake booster assembly.
7. Remove brake pedal attachment snap pin and clevis pin from inside the vehicle.
M
8. Remove nuts on brake booster and brake pedal assembly.
9. Remove brake booster assembly from dash panel.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of – 66.7 kPa (–
500 mmHg, –19.69 inHg) to brake booster.
2. Check output rod length.
Standard dimension when : 15.6 − 15.9 mm
vacuum – 66.7 kPa (– 500 (0.614 − 0.626 in)
mmHg, – 19.69 inHg)

SBR208E

Revision: January 2005 BR-17 2004 Pathfinder Armada

 BRAKE BOOSTER

INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length B (in
the figure) satisfies the specified value.
Length “B” : 125 mm (4.92 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 with clevis of input rod.
4. Install pedal bracket mounting nuts and tighten them to the
SGIA0060E
specified torque.
5. Install brake piping from brake master cylinder to ABS actuator. Refer to BR-11, "Hydraulic Circuit" .
6. Connect active boost and delta stroke sensor harness connectors to brake booster assembly.
7. Connect vacuum hose to brake booster.
8. Install master cylinder to booster assembly. Refer to BR-17, "Removal and Installation" .
9. Adjust the height and play of brake pedal.
10. Tighten lock nut of input rod to the specified torque.
11. Install engine air duct assembly. Refer to EM-14, "Removal and Installation" .
12. Install engine room cover. Refer to EM-11, "Removal and Installation" .
13. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .

Revision: January 2005 BR-18 2004 Pathfinder Armada

 VACUUM LINES

VACUUM LINES PFP:41920

A
Removal and Installation EFS0038E

LFIA0216E

1. Hose clip 2. Clamp 3. Vacuum hose E

4. Check valve

1. Disconnect vacuum hose from hose clip.

BR
2. Release clamps and disconnect vacuum hose.
3. Remove check valve from brake booster.
4. Installation is in the reverse order of removal. G
CAUTION:
● Insert vacuum hose for at least 24 mm (0.94 in).

● Do not use lubricating oil during assembly. H

SBR225B

Inspection EFS0038F
K
VISUAL INSPECTION
Check for improper assembly, damage and deterioration.
L
CHECK VALVE INSPECTION
Airtightness Inspection
Use a suitable vacuum pump to check. Connect to brake booster M
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: January 2005 BR-19 2004 Pathfinder Armada

 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

On-vehicle Inspection EFS0038G

PAD WEAR INSPECTION

● Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary.
Standard thickness : 11.88 mm (0.468 in)
Repair limit thickness : 1.0 mm (0.039 in)

BRA0010D

Components EFS003NV

WFIA0393E

1. Upper sliding pin 2. Sliding pin boot 3. Torque member bolt

4. Torque member 5. Piston seal 6. Piston
7. Inner pad 8. Pad retainer 9. Outer pad
10. Piston boot 11. Union bolt 12. Copper washer
13. Sliding pin bolt 14. Bleed valve 15. Cylinder body
16. Cap 17. Brake hose 18. Lower sliding pin

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

Revision: January 2005 BR-20 2004 Pathfinder Armada

 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 caliper assembly. 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-24, "BRAKE BURNISHING PROCEDURE" . C
Removal and Installation of Brake Pad EFS0038I

REMOVAL
1. Remove tires from vehicle using power tool. D
2. Remove lower sliding pin bolt.
3. Suspend cylinder body with a wire and remove pad and shim from torque member.
E
INSTALLATION
1. Push pistons in so that pad is firmly installed and mount cylinder body to torque member.
NOTE: BR
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 reservoir tank. Watch the level of the G
surface of reservoir tank.
2. Attach pad retainer to torque member.
CAUTION: H
When attaching pad retainer, attach it firmly so that it does
not float up higher than torque member, as shown in the fig-
ure.
I
3. Install lower sliding pin bolt and tighten it to the specified torque.
Refer to BR-20, "Components" .
4. Check brake for drag.
J
5. Install tires to the vehicle. Refer to WT-6, "Rotation" .

K
PFIA0273E

Removal and Installation of Brake Caliper Assembly and Disc Rotor EFS0038J

REMOVAL L
1. Remove tires from vehicle using power tool.
2. Drain brake fluid as necessary. Refer to BR-9, "Drain and Refill" .
NOTE: M
Do not remove union bolt unless removing brake caliper assembly from vehicle.
3. Remove union bolt as necessary and torque member bolts, then remove brake caliper assembly from the
vehicle.
NOTE:
Position brake caliper assembly aside using suitable wire, as necessary.
NOTE:
When servicing brake caliper, remove sliding pin bolts and caliper from torque member.
4. Remove disc rotor.
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 sliding pin bolts and torque member to caliper, if removed. Refer to BR-20, "Components" .

Revision: January 2005 BR-21 2004 Pathfinder Armada

 FRONT DISC BRAKE

3. Install caliper assembly to the vehicle, then tighten torque mem-

ber bolts to the specified torque. Refer to BR-20, "Components"
.
CAUTION:
● When attaching caliper assembly to the vehicle, wipe any
oil off knuckle spindle, washers and caliper assembly
attachment surfaces.
● Do not reuse caliper torque member bolts.

LFIA0209E

4. Install brake hose to brake caliper assembly, if removed, then

tighten union bolt to the specified torque. Refer to BR-20, "Com-
ponents" .
CAUTION:
● Do not reuse copper washers for union bolt.

● Attach brake hose to caliper assembly together with

union bolt and washers.

LFIA0214E

5. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
6. Attach tires to the vehicle. Refer to WT-6, "Rotation" .
Disassembly and Assembly of Brake Caliper Assembly EFS0038K

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 in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.

MAA0272D

4. Using a flat-bladed screwdriver, remove piston seal from cylin-

der body.
CAUTION:
Be careful not to damage cylinder inner wall.

SFIA1301E

Revision: January 2005 BR-22 2004 Pathfinder Armada

 FRONT DISC BRAKE

CALIPER INSPECTION
Cylinder Body A
CAUTION:
● 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 B
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. C
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
D
Piston
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
dition are observed. E
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface. BR
Sliding Pins, and Sliding Pin Boots
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part. G
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
H
ASSEMBLY
CAUTION:
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
I
1. Apply clean brake fluid to new piston seal and insert seal in to
groove on cylinder body.
CAUTION:
Do not reuse piston seal. J

L
WFIA0210E

2. Apply brake fluid to piston and piston boot, then install piston M
boot in to piston groove.
CAUTION:
Do not reuse piston boot.

WFIA0211E

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.
4. Install sliding pins and sliding pin boots to torque member.
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
Revision: January 2005 BR-23 2004 Pathfinder Armada
 FRONT DISC BRAKE

5. Install cylinder body. Tighten sliding pin bolt to the specified torque. Refer to BR-20, "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. (2 or more positions.)
2. Inspect runout using a dial gauge. (Measured at 10mm (0.39 in)
inside the disc edge.)
Runout limit (on vehicle) : 0.04 mm (0.0016 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.
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 : 26.0 mm (1.024 in)
Repair limit thickness : 24.5 mm (0.965 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: January 2005 BR-24 2004 Pathfinder Armada

 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

A
On-vehicle Inspection EFS0038L

PAD WEAR INSPECTION

● Inspect the thickness of pad through cylinder body inspection B
hole. Use a scale for inspection if necessary.
Standard thickness : 12.13 mm (0.478 in)
Repair limit thickness : 1.0 mm (0.039 in) C

BRA0010D
E
Components EFS0038M

BR

WFIA0236E

1. Union bolt 2. Brake hose 3. Copper washer

4. Cap 5. Bleed valve 6. Mounting bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Knuckle slide 12. Sliding sleeve boot
13. Sliding sleeve 14. Inner pad 15. Outer pad

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

Revision: January 2005 BR-25 2004 Pathfinder Armada

 REAR DISC BRAKE

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 caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
● Do not damage piston boot.
● 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-29, "BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake Pad EFS0038N

REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove mounting bolt from the top mount.
3. Swing cylinder body open, and remove pads.
INSTALLATION
1. Push piston in so that pad is firmly attached and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston.
CAUTION:
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.
3. Install top mounting bolt and tighten to specification.
4. Check brake for drag.
5. Install tires to the vehicle.
Removal and Installation of Brake Caliper Assembly and Disc Rotor EFS0038O

REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
3. Remove union bolt and mounting bolts, and remove brake cali-
per assembly.
4. Remove disc rotor.

LFIA0211E

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 caliper assembly to the vehicle, and tighten mounting bolts to specification. Refer to BR-25, "Com-
ponents" .
CAUTION:
Before installing caliper assembly to the vehicle, wipe off mounting surface of caliper assembly.
3. Install brake hose to caliper assembly and tighten union bolt to specification. Refer to BR-25, "Compo-
nents" .
CAUTION:
● Do not reuse copper washer for union bolt.

Revision: January 2005 BR-26 2004 Pathfinder Armada

 REAR DISC BRAKE

● Securely attach brake hose to protrusion on caliper assembly.

4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" . A
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper Assembly EFS0038P
B
DISASSEMBLY
1. Remove pads from cylinder body.
2. Remove sliding sleeve and boot from cylinder body. C
3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION: D
Do not get your fingers caught in piston.

BR
BRD0041D

4. Using a flat-bladed screwdriver, remove piston seal from cylin-

G
der body.
CAUTION:
Be careful not to damage cylinder inner wall.
H

PFIA0269E
J
CALIPER INSPECTION
Cylinder Body
CAUTION: K
● 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. L
● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
M
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 of 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.
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,
replace them.
ASSEMBLY
CAUTION:
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.

Revision: January 2005 BR-27 2004 Pathfinder Armada

 REAR DISC BRAKE

1. Apply clean brake fluid to new piston seal and insert in to

groove on cylinder body.
CAUTION:
Do not reuse piston seal.

WFIA0210E

2. Apply brake fluid to piston and to piston boot, then install piston
boot in to piston groove.
CAUTION:
Do not reuse piston boot.

WFIA0211E

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.
4. Install sliding boots and sleeves to cylinder body.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.
Runout Inspection
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 RAX-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: January 2005 BR-28 2004 Pathfinder Armada

 REAR 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 : 14.0 mm (0.551 in) B
Wear limit : 12.0 mm (0.472 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: January 2005 BR-29 2004 Pathfinder Armada

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EFS0038Q

Unit: mm (in)
Front brake Brake model CLZ31VC
Rotor outer diameter × thickness 320 × 26 (12.60 × 1.02)
Pad Length × width × thickness 111.0 × 73.5 × 9.5 (4.73 × 2.894 × 0.374)
Cylinder bore diameter 51 (2.01)
Rear brake Brake model AD14VE
Rotor outer diameter × thickness 320 × 14 (12.60 × 0.55)
Pad Length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Cylinder bore diameter 48 (1.89)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T

Diaphragm diameter 215 (8.46)

Recommended brake fluid Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent

Brake Pedal EFS0038R

Brake pedal height (from dash panel top surface) 182.3 − 192.3 mm (7.18 − 7.57 in)
Depressed pedal height [under a force of 490 N (50 kg, 110 lb)
More than 90.3 mm (3.55 in)
with engine running]
Clearance between stopper rubber and the threaded end of
0.74 − 1.96 mm (0.029 − 0.077 in)
stop lamp switch
Pedal play 3 − 11 mm (0.12 − 0.43 in)

Brake Booster EFS0038S

Input rod installation standard dimension 15.6 − 15.9 mm (0.614 − 0.626 in)

Check Valve EFS0038T

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)]

Front Disc Brake EFS0038U

Brake model CLZ31VC

Standard thickness (new) 11.88 mm (0.468 in)
Brake pad
Repair limit thickness 1.0 mm (0.039 in)
Standard thickness (new) 26.0 mm (1.024 in)
Repair limit thickness 24.5 mm (0.965 in)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015mm (0.0006 in)
Runout limit (with it attached to the vehicle) 0.04 mm (0.0016 in)

Revision: January 2005 BR-30 2004 Pathfinder Armada

 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear Disc Brake EFS0038V

A
Brake model AD14VE
Standard thickness (new) 12.13 mm (0.478 in)
Brake pad
Repair limit thickness 1.0 mm (0.039 in) B
Standard thickness (new) 14.0 mm (0.551 in)
Repair limit thickness 12.0 mm (0.472 in)
Disc rotor C
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)

BR

Revision: January 2005 BR-31 2004 Pathfinder Armada

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: January 2005 BR-32 2004 Pathfinder Armada