Mazda 323/MX-3/626/MX-6/Millenia/Protégé 1990-1998 and Ford Probe 1993-1997

Brake Caliper

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CAUTION
Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from brake surfaces! When cleaning brakes, use commercially available brake cleaning fluids.

REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the front brake caliper mounting



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Fig. Fig. 2: Common rear disc brake caliper mounting

1990-94 323, 626, MX3, MX6 and Protege
FRONT

See Figures 3, 4 and 5

  1. Raise the vehicle and support safely.
  2.  
  3. Remove the appropriate tire and wheel assembly.
  4.  



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Fig. Fig. 3: Use a short extension to help reach the caliper mounting bolts



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Fig. Fig. 4: Remove the mounting bolts and inspect for damaged threads. Replace if necessary



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Fig. Fig. 5: Lift the caliper from the knuckle and support it with wire

  1. If necessary, disconnect the flexible brake hose from the caliper.
  2.  
  3. If equipped with one caliper mounting bolt, remove the lower caliper bolt and pivot the caliper upward. Slide the top of the caliper off of the top pin and remove it from the vehicle (or support it with wire). If equipped with two caliper mounting bolts, remove both bolts and remove the caliper (or support it out of the way with wire).
  4.  

To install:
  1. If equipped with one mounting bolt, lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads. Install the mounting bolt. If equipped with two bolts, position the caliper and install the bolts.
  2.  
  3. Connect the brake hose to the caliper.
  4.  
  5. Bleed the brake system and inspect the brake system for proper operation.
  6.  
  7. Install the wheel and lower the vehicle. Connect the negative battery cable.
  8.  

REAR
  1. Raise the vehicle and support safely.
  2.  
  3. Remove the appropriate tire and wheel assemblies. Loosen the parking brake cable adjustment from inside the vehicle.
  4.  
  5. Disconnect the parking brake cable from the cable bracket and the operating lever.
  6.  
  7. Disconnect the flexible brake line from the caliper assembly.
  8.  
  9. Remove the caliper upper mounting bolt and pivot the caliper downward. Slide the caliper off of the guide pin. Remove the caliper from the vehicle.
  10.  

To install:
  1. Lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads.
  2.  
  3. Connect the brake hose to the caliper and tighten the hose nut to 16-20 ft. lbs. (22-26 Nm).
  4.  
  5. Install the upper caliper mounting bolt and tighten the bolt to 33-49 ft. lbs. (45-67 Nm).
  6.  
  7. Bleed the brake system and inspect the brake system for proper operation.
  8.  
  9. Install the wheel and lower the vehicle. Connect the negative battery cable.
  10.  

1995-98 Protege
FRONT
  1. Raise the vehicle and support safely.
  2.  
  3. Remove the appropriate tire and wheel assembly.
  4.  
  5. Disconnect the flexible brake hose from the caliper.
  6.  
  7. Remove the disc pad retaining pins. Remove the brake pads.
  8.  
  9. Remove the upper and lower caliper bolts. Remove the caliper from the vehicle.
  10.  

To install:
  1. Position the caliper on the brake disc. Install the caliper mounting bolts and tighten the bolts to 29-36 ft. lbs. (40-49 Nm).
  2.  
  3. Install the disc pad and retaining pins.
  4.  
  5. Replace the washers for the brake line. Connect the brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm).
  6.  
  7. Bleed the brake system and inspect the brake system for proper operation.
  8.  
  9. Install the wheel and lower the vehicle.
  10.  

REAR
  1. Raise the vehicle and support safely. Remove the wheels.
  2.  
  3. Disconnect the parking brake cable from the cable bracket and the operating lever.
  4.  
  5. Disconnect the flexible brake line from the caliper assembly.
  6.  
  7. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the caliper piston inward (turn until it stops).
  8.  
  9. Remove the caliper mounting bolts. Remove the caliper from the vehicle.
  10.  
  11. Installation is reverse of removal. Torque the caliper mount bolts to 34-44 ft. lbs. (46-60 Nm). Torque the brake hose line bolt to 16-22 ft. lbs. (22-30 Nm). Properly bleed the brake system.
  12.  

1995 MX3
FRONT
  1. Raise the vehicle and support safely.
  2.  
  3. Remove the appropriate tire and wheel assembly.
  4.  
  5. Disconnect the flexible brake hose from the caliper.
  6.  
  7. Remove the disc pad retaining pins. Remove the brake pads.
  8.  
  9. Remove the upper and lower caliper bolts. Remove the caliper from the vehicle.
  10.  

To install:
  1. Position the caliper on the brake disc. Install the caliper mounting bolts and tighten the bolts to 29-36 ft. lbs. (40-49 Nm).
  2.  
  3. Install the disc pad and retaining pins.
  4.  
  5. Replace the washers for the brake line. Connect the brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm).
  6.  
  7. Bleed the brake system and inspect the brake system for proper operation.
  8.  
  9. Install the wheel and lower the vehicle. Connect the negative battery cable.
  10.  

REAR
  1. Raise the vehicle and support safely.
  2.  
  3. Remove the wheels. Loosen the parking brake cable adjustment from inside the vehicle.
  4.  
  5. Disconnect the parking brake cable from the cable bracket and the operating lever.
  6.  
  7. Disconnect the flexible brake line from the caliper assembly.
  8.  
  9. Remove the caliper upper mounting bolt and pivot the caliper downward. Slide the caliper off of the guide pin. Remove the caliper from the vehicle.
  10.  

To install:
  1. Lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads.
  2.  
  3. Connect the brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm).
  4.  
  5. Install the upper caliper mounting bolt and tighten the bolt to 12-17 ft. lbs. (16-24 Nm).
  6.  
  7. Connect the parking brake cable to the cable bracket and the operating lever.
  8.  
  9. Bleed the brake system and inspect the brake system, including the parking brake, for proper operation.
  10.  
  11. Install the wheel and lower the vehicle. Connect the negative battery cable.
  12.  

1995-98 626 and MX6
FRONT
  1. Raise the vehicle and support safely.
  2.  
  3. Remove the appropriate tire and wheel assembly.
  4.  
  5. Disconnect the flexible brake hose from the caliper.
  6.  
  7. Remove the lower caliper bolt and pivot the caliper upward. Slide the top of the caliper off of the top pin and remove it from the vehicle.
  8.  

To install:
  1. Lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads.
  2.  
  3. Connect the brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm).
  4.  
  5. Install the caliper mounting bolt and tighten the bolt to 22-29 ft. lbs. (30-40 Nm).
  6.  
  7. Bleed the brake system and inspect the brake system for proper operation.
  8.  
  9. Install the wheel and lower the vehicle. Connect the negative battery cable.
  10.  

REAR
  1. Disconnect the battery negative cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the appropriate tire and wheel assemblies. Loosen the parking brake cable adjustment from inside the vehicle.
  6.  
  7. Disconnect the parking brake cable from the cable bracket and the operating lever.
  8.  
  9. Disconnect the flexible brake line from the caliper assembly.
  10.  
  11. Remove the caliper upper mounting bolt and pivot the caliper downward. Slide the caliper off of the guide pin. Remove the caliper from the vehicle.
  12.  

To install:
  1. Lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads.
  2.  
  3. Connect the brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm).
  4.  
  5. Install the upper caliper mounting bolt and tighten the bolt to 26-28 ft. lbs. (35-39 Nm).
  6.  
  7. Connect the parking brake cable to the cable bracket and the operating lever.
  8.  
  9. Bleed the brake system and inspect the brake system, including the parking brake, for proper operation.
  10.  
  11. Install the wheel and lower the vehicle. Connect the negative battery cable.
  12.  

1995-98 Millenia
FRONT
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the brake hose and brake pipe. Cap the ends to prevent contamination.
  6.  
  7. Remove the caliper mounting bolts and remove the caliper. Remove the brake rotor.
  8.  
  9. Installation is the reverse of removal. Torque the caliper mounting bolts to 47-62 ft. lbs. (63-84 Nm). Add fluid and properly bleed the brake system.
  10.  

REAR
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the brake hose and cap the end to prevent contamination.
  6.  
  7. Remove the caliper bracket mounting bolts and remove the caliper. Remove the rotor.
  8.  
  9. Installation is the reverse of removal. Torque the caliper mounting bolts to 12-17 ft. lbs. (16-23 Nm).
  10.  

OVERHAUL



See Figures 6 through 15



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the front brake caliper assembly



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the rear disc brake caliper assembly

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

      Click image to see an enlarged view

      Fig. Fig. 8: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



      Click image to see an enlarged view

      Fig. Fig. 9: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper. .
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 11: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 12: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 13: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



Click image to see an enlarged view

Fig. Fig. 14: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



Click image to see an enlarged view

Fig. Fig. 15: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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