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Author Topic: Brake Booster Replacement - 2000-4 Xterra & 1999-04 Frontier  (Read 799 times)

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Offline pinchel (Rob)

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So if you get a stiff pedal all the sudden, chances are your brake pedal might have had excessive travel and you were used to it being that way, like us. My Xterra has over 230k miles but I can't say I recall when it changed. The brakes worked so I didn't think much about it, until the pedal went stiff half way into the trail on our way to Sheeps Bridge (The Back Way).

So here is the OEM part you need, Nissan 47210-7B400. Assuming you do not have a bad check valve, which I have yet to find the part # for, this is all you need. Be sure to reference this part#, because at the time of doing my part ordering, ALL of the parts places in town had the same incorrect part number which does not fit or work correctly. I found this out after swapping parts mulitple times and ultimately contact the part manufacturer.

The manufacturer then realized there was a catalog issue. Awesome. Hopefully after me alerting them all the vendors who sell it will fix that. So, everyone was saying I needed aftermarket part 53-6009, when in fact we need 53-6006.

It's really simple, but you'll have to removed some brackets and bolts in the engine bay to make room to remove the booster. I'll post pics later of the parts I moved.

Slide off the vacuum hose by either removing the clip or sliding it up above the barb.

Remove the 2 nuts to pull away the Master Cylinder, being careful not to kink the metal brake lines.

Remove the 4 nuts underneath the dash, start with the top right nut, then bottom right, then top left, then bottom left. If you do not do it in this order you will likely end up making this way harder.

Remove the cotter pin from the bolt attached to the brake pedal. Slide lock pin out.

Pull out brake booster slightly, then from the inside loosen the lock nut holding the clevis tight. Remove the clevis while under the dash. This helps to remove the booster by giving you more clearance space.

I am not sure how best to get the thing out but take your time and think it through, I had the best luck getting the 5 bolts to face up and over the metal brake lines.

Be sure to save the metal 1/4" spacer, the paper gasket, lock nut, clevis, lock pin & cotter pin. You may not have the spacer and gasket. I didn't replace my gasket.
« Last Edit: July 28, 2016, 08:13:10 AM by pinchel (Rob) »
Click here to see my rig.  Get your AZXC/AZTC/AZFC Forum Decals here  VinylTats!