Mazda Car 2002-04

Brake Disc (Rotor)

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Retaining clip
     
    Cap from the caliper bolts
     
    Caliper mounting bolts and the caliper.
     

  4.  
  5. Remove the rotor.
  6.  

To install:

  1. Install or connect the following:

    Rotor
     
    Caliper. Torque the caliper mounting bolts to 19-22 ft. lbs. (25-30 Nm). Install the bolt caps.
     
    Brake hose to the caliper. Tighten the flare nut while holding the hose at location A shown in the accompanying illustration with an open end wrench. Tighten the nut to 10-15 ft. lbs. (14-21 Nm) and make sure the brake hose is not twisted, if it is unfasten the flare nut and retighten making sure the brake line remains straight. Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
     
    Retaining clip
     
    Wheels
     

  2.  
  3. Pump the brake pedal several times to seat the pads.

    Click image to see an enlarged view

    Fig. Exploded view of the front disc brakes-Mazda3



    Click image to see an enlarged view

    Fig. Tighten the brake hose flare nut while holding the hose at point A-Mazda3

  4.  



Click image to see an enlarged view

Fig. Exploded view of the front disc brakes-Mazda6 and Mazdaspeed6 models

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Cap from the caliper bolts
     
    Caliper mounting bolts and the caliper
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Rotor
     
    Caliper. Torque the caliper mounting bolts to 36--39 ft. lbs. (49-54 Nm). Install the bolt caps.
     
    Brake hose to the caliper. Tighten the bolt to 16-21 ft. lbs. (21-29 Nm) and make sure the brake hose is not twisted. Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
     
    Wheels
     

  2.  
  3. Pump the brake pedal several times to seat the pads.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    Caliper mounting bolts and the caliper
     
    Brake pads, shims and pin
     

  6.  
  7. Using Mazda tool 49-0221-600C and the old inner brake pad, push the caliper piston into the caliper bore.

    Guide plate
     
    Mounting support bolts and support

    Click image to see an enlarged view

    Fig. Using Mazda tool 49-0221-600C and the old inner brake pad, push the caliper piston into the caliper bore-626

     

  8.  

To install:

  1. Install or connect the following:

    Mounting support and bolts. Tighten the bolts to 58-75 ft. lbs. (79-101 Nm)
     
    Guide plate
     
    Brake pads and shims to the caliper support
     
    Caliper over the brake pads
     
    Caliper mounting bolt and torque to 22-28 ft. lbs. (30-41 Nm)
     
    Wheels
     

  2.  
  3. Test the brakes for proper operation.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Flexible brake hose from the caliper
     
    Upper and lower caliper bolts
     
    Caliper from the vehicle
     
    Brake pads and hardware
     
    Mounting support bolts and the mounting support
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Rotor
     
    Mounting support and tighten the bolts to 37-50 (50-68 Nm).
     
    Brake pads and hardware
     
    Caliper on the brake disc
     
    Caliper mounting bolts and tighten the bolts to 58-65 ft. lbs. (79-88 Nm)
     

  2.  
  3. Replace the washers for the brake line.

    Brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm)
     

  4.  
  5. Bleed the brake system and inspect the brake system for proper operation.
  6.  
  7. Install the wheels.

    Click image to see an enlarged view

    Fig. Front disc brakes-Miata

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose and brake pipe.
     
    Caliper mounting bolts and the caliper
     
    Guide plate
     
    Mounting support bolts and the mounting support
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Mounting support and bolts. Tighten the bolts to 76-101 (102-137 Nm).
     
    Guide plate
     
    Caliper. Torque the caliper mounting bolts to 47-62 ft. lbs. (63-84 Nm).
     
    Brake hose and pipe and tighten to 15-21 ft. lbs. (22-29 Nm). Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
     
    Wheels

    Click image to see an enlarged view

    Fig. Front disc brakes-Millenia

     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Flexible brake hose from the caliper
     
    Cap on type A brakes or bolt on type brakes
     
    Spring on type A brakes
     
    Brake pads
     
    Upper and lower caliper bolts
     
    Caliper
     
    Guide plate
     
    Mounting support bolts and the mounting support
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Mounting support and bolts. Tighten the bolts to 58-75 (79-101 Nm).
     
    Guide plate
     
    Caliper on the brake disc
     
    Caliper mounting bolts and tighten the bolts on A type brakes to 37-39 ft. lbs. (50-53 Nm) or 16-23 ft. lbs. (22-31 Nm) on type B brakes
     
    Brake pads
     
    Spring on type A brakes
     

  2.  
  3. Replace the washers for the brake line.

    Brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm)
     

  4.  
  5. Bleed the brake system.
  6.  
  7. Install the wheels.

    Click image to see an enlarged view

    Fig. Exploded view of the type A and B brake systems-Protégé with disc brakes

  8.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Retaining clip
     
    Cap from the caliper bolts
     
    Caliper mounting bolts and the caliper.
     

  4.  
  5. Remove the rotor.
  6.  

To install:

  1. Install or connect the following:

    Rotor
     
    Caliper. Torque the caliper mounting bolts to 19-22 ft. lbs. (25-30 Nm). Install the bolt caps.
     
    Brake hose to the caliper. Tighten the flare nut while holding the hose at location A shown in the accompanying illustration with an open end wrench. Tighten the nut to 10-15 ft. lbs. (14-21 Nm) and make sure the brake hose is not twisted, if it is unfasten the flare nut and retighten making sure the brake line remains straight. Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
     
    Retaining clip
     
    Wheels
     

  2.  
  3. Pump the brake pedal several times to seat the pads.

    Click image to see an enlarged view

    Fig. Exploded view of the front disc brakes-Mazda 3

  4.  



Click image to see an enlarged view

Fig. Exploded view of the front disc brakes-Mazda 6 models

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Cap from the caliper bolts
     
    Caliper mounting bolts and the caliper
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Rotor
     
    Caliper. Torque the caliper mounting bolts to 36--39 ft. lbs. (49-54 Nm). Install the bolt caps.
     
    Brake hose to the caliper. Tighten the bolt to 16-21 ft. lbs. (21-29 Nm) and make sure the brake hose is not twisted. Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
     
    Wheels
     

  2.  
  3. Pump the brake pedal several times to seat the pads.
  4.  

 
label.common.footer.alt.autozoneLogo