How do I Replace Brakes on a Nissan 2002 Pathfinder

The 2002 Nissan Pathfinder SUV uses a braking system made up of front disc brakes and rear drum brakes. Both front and rear brakes operate using a hydraulic system that controls pistons in the brake assemblies. Unless there is a problem with a specific component, routine maintenance consists of replacing the pads on the front brakes and the shoes on the rear brakes. Replacing the pads should only take about an hour, but replacing the shoes is more complicated and will take longer for inexperienced owners.

Instructions

Front Disc Brakes

1

Open the hood, and remove the master cylinder cap. Place a clean rag over the master cylinder to prevent contamination of the brake fluid. Place rags below the master cylinder to catch any fluid that overflows.

2

Loosen the lug nuts on the front wheels, and raise the vehicle with a jack. Support both sides with a jack stand, and remove the lug nuts and wheels. Place wheel blocks around the rear wheels.

3

Place a drip pan under the brake assembly, and saturate the entire assembly with brake cleaner. This is to remove the dangerous brake dust that accumulates due to pad wear. Allow the assembly to air dry.

4

Use a socket wrench to loosen the lower pin bolt by turning it counterclockwise. Finish removing the bolt by hand.

5

Lift the cylinder body up, off the rotor, and secure it in place with a piece of wire or string to avoid placing strain on the brake line.

6

Remove the inner and outer pad retainers from the cylinder body, and pull out the inner and outer pads and shims.

7

Attach a large C-clamp over the pistons, and tighten the clamp to force the pistons back into the cylinder. This is to make room for the thicker new pads.

8

Apply a coat of high temperature grease to the back of the new pads, then attach the shims. Place a coat of grease to the back of the shims. Insert the new pads into the cylinder housing, and replace the retainers. Make sure the pads are seated all the way against the rim of the housing.

9

Use a piece of No. 120 emery paper to smooth both sides of the brake rotor. If you see deep grooves in the rotor, you should take it to a machine shop to be resurfaced.

10

Rotate the cylinder down onto the rotor. Replace the lower pin bolt, and use a torque wrench to tighten it to 24 to 31 foot-lbs. of torque. Repeat the procedure on the opposite brake assembly.

11

Replace the wheels and lug nuts, and lower the vehicle. Check the master cylinder to ensure the fluid level reaches the "Full" level. Add new brake fluid if necessary. Replace the master cylinder cap.

12

Drive the vehicle on a road with little traffic. Accelerate to approximately 30 mph, and quickly decelerate to a near stop. Repeat this several times to seat the new pads.

Rear Drum Brakes

13

Ensure the parking brake is released.

14

Loosen the lug nuts on the rear wheels, and raise the rear of the vehicle. Place wheel blocks around the front wheels. Support the vehicle with jack stands, remove the lug nuts and take off both rear wheels.

15

Place a drip pan below the brake assembly, and clean the components with brake cleaner.

16

Remove the brake drum by pulling it off the wheel lug bolts.

17

Remove the shoe hold-down pins from both shoes. Place the spring removal tool over the springs on the front of the shoes while you hold the pin in place from behind the backing plate. Rotate the spring retainer counterclockwise to release the locking plate, and remove the pins.

18

Remove the upper and lower return springs from the shoes. It might be possible to do this by grasping the outside edge of the shoe and pulling it out and towards the center at the same time. If this doesnt work, use a slotted screwdriver or brake tool to pry the springs off the shoes. Remove the shoes.

19

Remove the adjuster from below the cylinder, noting the direction it faces. This is a cylindrical piece with slots on each end that maintains tension on the shoes. Unscrew the adjuster, and apply lithium grease to the threads. Reassemble the adjuster.

20

Disconnect the parking brake cable from the toggle lever, which is connected to the back of the front shoe. Use a slotted screwdriver to remove the retainer ring from the toggle lever, and separate the lever from the brake shoe.

21

Smooth the inside of the brake drum using No. 120 emery paper. If the drum has deep grooves cut into it, take it to a machine shop for resurfacing.

22

Connect the toggle lever to the new front brake shoe. The front shoe is the shorter of the two shoes. Attach the parking brake cable to the toggle lever.

23

Place the new shoes into place. Replace the hold-down pins. Lock them into place by turning the retaining spring tool clockwise. Attach the upper and lower return springs to both shoes. Place the adjuster between the top ends of the brake shoes, being careful to orient it in the proper direction. Rotate the wheel on the adjuster to expand it until it is putting tension on the shoes.

24

Compare the side you just replaced with the opposite side to ensure all components are properly installed. Repeat the procedure on the opposite side.

25

Replace the brake drums. If the drums slip on easily, remove them and expand the adjusters slightly more. Continue to do this until you feel resistance when you replace the drum.

26

Replace the wheels and lug nuts. Lower the vehicle, and tighten the lug nuts. Drive the vehicle forward, and backwards several times, frequently applying the brakes, to adjust them.

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