Brake Caliper (Rear) - Clunk/Rattle/Knocking Noise

Classification:
BR01-002A

Reference:
ITB01-061A

Date:
January 31, 2002

2001 I30, 2002 I35, AND 2001-2002 G20 REAR CALIPER
CLUNK, RATTLE, OR KNOCKING NOISE

ATTENTION:
This bulletin Amends the Applied Vehicles, VINS, And Dates sections of ITB01-061. Please discard all paper copies of ITB01-061.

APPLIED VEHICLES:
2001 I30 (CA33)
2002 I35 (CA33)
2001-2002 G20 (P11)

APPLIED VINS:

2001 I30 - All Vehicles
2002 I35 - Vehicles - Vehicles built before: JNKDA31A92T007116
2001-2002 G20 - Vehicles built before: JNKCP11A22T510842

APPLIED DATES:

2001 I30 - All Vehicles
2002 I35 - Vehicles built before: September 20, 2001
2001-2002 G20 - Vehicles built before: October 22, 2001

SERVICE INFORMATION

If an Applied 2001 I30, 2002 I35, or 2001-2002 G20 exhibits the following symptoms:

^ A clunk, knock, or rattle noise from the rear of the vehicle while driving on rough road surfaces or over harsh bumps,

It may be caused by the brake pads moving in the brake caliper housing.

A replacement Spring Retainer (SPR-RET) kit, consisting of replacement pad retainers, inner and outer shims, and brake pads is available to address this condition. Use the Service Procedure provided in this bulletin to diagnose and repair this incident, if it should occur.

SERVICE PROCEDURE

1. Test drive the vehicle under the conditions described in the Service Information section to confirm the symptoms exist.

NOTE:
Lightly apply the parking brake while the incident is occurring to verify if the noise is reduced or eliminated.

^ If application of the parking brake does not reduce or eliminate the noise, this bulletin does not apply. Use other appropriate Service Manual procedures to further investigate the source of the noise.

^ If application of the parking brake does reduce or eliminate the noise, proceed to step 2 below.

2. Remove the rear wheels.

Starting with the left rear:





3. Remove the brake caliper assembly pin bolts (see Figure 1).





4. Loosen the parking brake cable by removing the parking brake cable bolt (see Figure 2).

5. Remove the brake caliper assembly to gain access to the brake pad, shim, and pad retainer.

WARNING:
DO NOT allow the brake caliper assembly to hang from the brake hose. Use a piece of wire to hang the caliper from the rear coil spring.

6. Remove the left brake pad, shim, and pad retainer.





7. Use Nissan Brake Cleaner (P/N 999MP-A3042) to remove PBC (Poly Butyl Cuprysil) grease and/or brake dust from the torque member (see Figure 3).





8. Remove the red plastic tabs from one of the replacement pad retainers in the SPR-RET kit (see the PARTS INFORMATION section of this bulletin) and install the replacement pad retainer (see Figure 4).

9. Repeat step 8 for the other replacement pad retainer.

10. Install inner and outer brake pads, outer shim, and new inner shim from the SPR-RET kit.





NOTE:
Use PBC grease (Nissan P/N 99990-00939P) between the brake pad, shim, and piston to reduce potential noise. Be sure to put the inner and outer shims in the correct location (see Figure 5).

11. Carefully push the piston back into the brake caliper body. For more information, reference the ESM, Section BR/BRAKE SYSTEM/REAR DISC BRAKE/Pad Replacement/BR-28 through BR-30 for 2001 I30 vehicles, BR-27 through BR-29 for 2002 135 vehicles, and BR-24 through BR-26 for 2001 and 2002 G20 vehicles.

WARNING:
DO NOT try to force the piston back into the brake caliper. Caliper damage may result.

12. Reinstall the brake caliper assembly to its original location.

13. Reattach the left upper and lower caliper assembly pin bolts. Torque the bolts to proper torque specifications (i.e. 22-31 N-m, 2.2 - 3.2 Kg-m, 16 - 23 ft-lb).

14. Reinstall the parking brake cable bolt.

15. Repeat steps 3 through 14 for the right rear brake.

16. Reinstall the rear wheels.

NOTE:
When re-installing the wheels, evenly torque the wheel lug nuts to the proper torque specification (i.e., 98 - 118 N-m, 10 - 12 Kg-m, 72 - 87 ft-lb). Do not tighten the wheel lug nuts with an air impact driver.

17. Repeat step 1 to test drive the vehicle and verify the noise is no longer present.





PARTS INFORMATION

CLAIMS INFORMATION





Submit a Primary Failed Part (PP) line claim using the claims coding shown.