Started knocking the list down!
Okay so I had my Z16 brake kit to install (remember I got that the same time as the TJM Treds and the Jerry can?), I was knocking it out without fail.. or so I thought.
Thanks to Stioc for the reminder that xterra and frontiers have the same brake system we do so there should be a youtube video. And a big thanks to Allof75 for helping
me throughout the process. Everything was going well then there was two tiny little screws that hold this retaining washer in. Well when I opened it up those 2 screws were
already pretty stripped and were tight as all heck! That took some fun negotiating with a screw-driver and a mallet to force them out (do you guys know how hard it is to find
2 Phillips head machine screws with a 8/32 thread that are counter sunk, stainless steel and only 1/4" long at a store???) anyways bought 4 new ones and started after it again.
Everything else was going pretty well then I go to put the caliper back on with the new rotors and pads and the caliper is too skinny. I think to myself 'You have got to be
joking!' Turns out the pistons just were not pushed back all the way (quick question, is that bad if they don't go all the way out when the brake is off? I would think not that way
there is not a lag from when you apply the pedal to when it brakes but if anyone can verify?) So I got a clamp and pushed them back in and they fit nice. If you take out the
time that was excitingly spent finding those new screws and trying to get the old ones out, then take out the time spent trying to figure out why the caliper was too small...
The project didn't take too long.
![Smile :) :)](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
So now everything is put back together, brakes have much more bite to them with the same pedal feel to them and the brakes no longer
squeak. I call that a good check off the list.
`
![IMG_0795 (1).jpg IMG_0795 (1).jpg](https://expeditionportal.com/forum/data/attachments/175/175780-2e61271f9f261be17f8fb8482c408f03.jpg)
`
The next on the list was to make the screen underneath my bumper small. The expanded metal I originally put there has very large holes and I'm sure that it wouldn't stop anything
except a large boulder (which it would be too flimsy for anyways). So I went out and purchased expanded metal but in a much smaller pattern. My original plan was to weld it on, then
I remembered how fast I blew through the first stuff so I just zip-tied it up for now. Looking to bolt it in eventually but I am done spending money for a good while. I like the way it
turned out and its not very noticeable.
`
![IMG_0796 (1).jpg IMG_0796 (1).jpg](https://expeditionportal.com/forum/data/attachments/175/175781-1ab5a5ff0ba03514d4d1264c07860e45.jpg)
`
Last on the list was the replacement of my extremely annoying upper sway bar link. This was a total nightmare let me tell you. So first off the reason it was clanking around was because
the top nut would not tighten anymore so the link was loose and thus able to lift and drop causing a noise on every single bump. I though to myself 'oh I'm going to hit it with pb blaster
and when I wake up it should be good to loosen up and come right out. How wrong I was! The bolts on the top and bottom are held tight with a hex key (allen wrench) and the nut spins
tightening the link to the strut and sway bar. Well the spot for the hex key at the top was completely stripped to a circle! And of course the nut was on tighter than all heck. So I jumped to
do the bottom one, the hex key fit like a cheap charm and I put the wrench on it and started loosening it. Finally! It was tight but started loosening smooth; I was in luck! NOPE!! that lovely
smooth feeling was the wrench rounding the nut. HAHA...seriously!?! So at this point I was fed up, out came the grinder with a cut off wheel at first to cut through the bolts, the a grinding
wheel to get the pieces out. This took so much less time (just like cutting the bolts on the control arms...what a trend). Anyways so the new link went on all nice and now the front end is
more stiff..just when I though I had made it smooth... but no more noise so I don't even care. That sway bar will never again come off If I can help it.
`
Here is the carnage. Honestly though it was pro cutting skills, the strut and sway bar were barely nicked :coffeedrink:
![IMG_0800 (1).jpg IMG_0800 (1).jpg](https://expeditionportal.com/forum/data/attachments/175/175783-c71a7df2466ccb836bb20e43438bc6ea.jpg)
`
Voila!
`
![IMG_0798 (1).jpg IMG_0798 (1).jpg](https://expeditionportal.com/forum/data/attachments/175/175786-06185aec70c59502892c6739d1a2fe79.jpg)
`
Well now I am more content. I am waiting for the other CV axle to arrive and the rest of the bushings and will make another looong weekend out of those. I am hoping the popping noise myself
and Allof75 are experiencing is fixed with the CV replacement. Anyways that's all for now. Tonight I may try and cut the light hoop down slightly on the driver side (its maybe 1/8" off) and re-weld it.
`
Cheers