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

Brake Pads

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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 typical front brake pad components



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Fig. Fig. 2: Exploded view of the rear disc brake pad components

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

See Figures 3, 4, 5, 6, 7 and 8



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Fig. Fig. 3: Loosen the lower guide pin ...



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Fig. Fig. 4: ... then remove it from the caliper



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Fig. Fig. 5: Rotate the caliper upwards to access the pads



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Fig. Fig. 6: The pads can now be removed from the caliper mounting support



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Fig. Fig. 7: Remove and inspect the guide plates. Replace if damaged



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Fig. Fig. 8: Before installing the pads, seat the caliper piston into its bore

  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the appropriate tire and wheel assemblies.
  6.  
  7. If equipped with 1 lower caliper mounting bolt, remove the caliper lower mounting bolt and pivot the caliper up and support it. If equipped with 2 caliper mounting bolts, remove both and support the caliper with mechanics wire. Do not kink the brake line or allow the caliper to hang by the brake line.
  8.  
  9. Remove the brake pads, shims and if so equipped, pins. Take note of positioning to aid installation.
  10.  
  11. If the caliper is single piston design, push the caliper back into the bore with a C-clamp or other suitable tool. If the caliper is a 4 piston type caliper, use Mazda tool 49-0221-600C or equivalent and the old inner brake pad, push the caliper piston(s) into the caliper bore.
  12.  

To install:
  1. Install the brake pads and shims to the caliper support. Install the caliper over the brake pads.
  2.  

Be careful that the piston boot does not become caught when lowering the caliper onto the support. Do not twist the brake hose during caliper installation.

  1. Install the caliper mounting bolt(s).
  2.  
  3. Install the tire and wheel assemblies.
  4.  
  5. Lower the vehicle and test the brakes for proper operation.
  6.  

REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  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. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads. Do not allow the caliper to hang by the brake line.
  10.  
  11. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.
  12.  

To install:
  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  

Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  1. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 12-17 ft. lbs. (16-23 Nm). Attach the parking brake cable to the operating lever and tighten the locknut to 12-17 ft. lbs. (16-23 Nm).
  2.  
  3. Start the engine and forcefully depress the brake pedal 5-6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  4.  
  5. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  6.  
  7. Install the tire and wheel assemblies. Lower the vehicle.
  8.  
  9. Test the brakes for proper operation.
  10.  

1995-98 Protege
FRONT
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the appropriate tire and wheel assemblies.
  6.  
  7. Remove the spring and the pin.
  8.  
  9. Remove the two pad pins from the brake pads.
  10.  
  11. Remove the brake pads and shim. Take note of positioning to aid installation.
  12.  
  13. Push the caliper piston into the caliper bore.
  14.  

To install:
  1. Install the brake pads and shims to the caliper.
  2.  
  3. Insert the pad pins and spring.
  4.  
  5. Install the tire and wheel assemblies.
  6.  
  7. Lower the vehicle and test the brakes for proper operation.
  8.  

REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the wheels. 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. Remove the screw plug. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston inward (turn until it stops).
  8.  
  9. Remove the upper caliper mounting bolt and pivot the caliper upward off of the pads.
  10.  
  11. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.
  12.  

To install:
  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  

Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  1. Lubricate and install the bottom caliper mounting bolt. Tighten the bolt to 33-44 ft. lbs. (46-60 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 9-11 ft. lbs. (12-15 Nm).
  2.  
  3. Start the engine and forcefully depress the brake pedal 5-6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  4.  
  5. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  6.  
  7. Install the tire and wheel assemblies. Lower the vehicle.
  8.  
  9. Test the brakes for proper operation.
  10.  

1995 MX3
FRONT
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the appropriate tire and wheel assemblies.
  6.  
  7. Remove the spring and the pin.
  8.  
  9. Remove the two pad pins from the brake pads.
  10.  
  11. Remove the brake pads and shim. Take note of positioning to aid installation.
  12.  
  13. Using Mazda tool 49-0221-600C or equivalent and the old inner brake pad, push the caliper piston into the caliper bore.
  14.  

To install:
  1. Install the brake pads and shims to the caliper.
  2.  
  3. Insert the pad pins and spring.
  4.  
  5. Install the tire and wheel assemblies.
  6.  
  7. Lower the vehicle and test the brakes for proper operation.
  8.  

REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the wheels. 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. Remove the screw plug.
  8.  
  9. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads. Do not allow the caliper to hang by the brake line.
  10.  
  11. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.
  12.  

To install:
  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  

Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  1. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 12-17 ft. lbs. (16-24 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 105-138 inch lbs. (12-16 Nm).
  2.  
  3. Start the engine and forcefully depress the brake pedal 5-6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  4.  
  5. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  6.  
  7. Install the tire and wheel assemblies. Lower the vehicle.
  8.  
  9. Test the brakes for proper operation.
  10.  

1995-98 626 and MX6
FRONT
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the appropriate wheel assemblies.
  6.  
  7. Remove the caliper lower mounting bolt and pivot the caliper up and support it. Do not kink the brake line.
  8.  
  9. Remove the brake pads, shims and pin. Take note of positioning to aid installation.
  10.  
  11. Using Mazda tool 49-0221-600C or equivalent and the old inner brake pad, push the caliper piston into the caliper bore.
  12.  

To install:
  1. Install the brake pads and shims to the caliper support. Install the caliper over the brake pads.
  2.  

Be careful that the piston boot does not become caught when lowering the caliper onto the support. Do not twist the brake hose during caliper installation.

  1. Install the caliper mounting bolt and torque to 22-29 ft. lbs. (30-40 Nm).
  2.  
  3. Install the tire and wheel assemblies.
  4.  
  5. Lower the vehicle and test the brakes for proper operation.
  6.  

REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1 / 2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  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. Remove the screw plug.
  8.  
  9. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads. Do not allow the caliper to hang by the brake line.
  10.  
  11. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.
  12.  

To install:
  1. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
  2.  

Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  1. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 26-28 ft. lbs. (35-39 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 105-138 inch lbs. (11.8-15.6 Nm).
  2.  
  3. Start the engine and forcefully depress the brake pedal 5-6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  4.  
  5. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  6.  
  7. Install the tire and wheel assemblies. Lower the vehicle.
  8.  
  9. Test the brakes for proper operation.
  10.  

1995-98 Millenia
FRONT
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the bottom caliper lock pin and swing the caliper upwards.
  6.  
  7. Remove the V-springs and remove the pads and shims.
  8.  
  9. Press the caliper pistons back into their cylinders. Installation is the reverse of removal. Torque the lock pin to 47-62 ft. lbs. (63-84 Nm). Bleed the brake system if necessary.
  10.  

REAR
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the lock pin and rotate the caliper upwards.
  6.  
  7. Remove the V-springs and remove the pads. Remove the shims from the pads.
  8.  
  9. Press the caliper piston back into the cylinder. Installation is the reverse of removal. Torque the lock pin to 37-50 ft. lbs. (50-68 Nm). Bleed the brake system if necessary.
  10.  

INSPECTION



The front brake pads have built in wear indicators that contact the brake disc when the brake pad thickness becomes too thin and emit a squealing sound to warn the driver.

Inspect the thickness of the brake linings by looking through the brake caliper body check port. The thickness limit of the lining is 0.08 in. (2.0mm) except on 1995-98 626, MX6, Millenia. On 1995-98 626, MX6, Millenia, the limit is 0.04 in. (1.0mm).

When the limit is exceeded, replace the pads on both sides of the brake disc and also the brake pads on the wheel on the opposite side of the vehicle. Do not replace just one pad on a side without replacing the other pad on the same wheel as well as the brake pads on the other front wheel.

If there is a significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston, lock pin sleeve and guide pin sleeve.

 
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