Mazda Car 2002-04

Brake Caliper

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Removal & Installation



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

    Wheels
     
    Parking brake cable
     
    Brake pipe from the hose and the clip
     
    Pad retaining clip
     
    Caps from the caliper bolts
     
    Caliper brake hose
     
    Caliper mounting bolts and the caliper
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Torque the caliper mounting bolts to 19-22 ft. lbs. (25-30 Nm). Install the bolt caps.
     
    Brake hose and pipe and tighten to 14-16 ft. lbs. (19-23 Nm). Reinstall a new clip and fill the master cylinder with clean brake fluid and bleed the hydraulic system.
     
    Pad retaining clip and parking brake cable
     
    Wheels
     

  2.  
  3. Pump the brake pedal several times to seat the pads. Inspect the parking brake lever stroke and brake drag and adjust as necessary.

    Click image to see an enlarged view

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

  4.  



Click image to see an enlarged view

Fig. Exploded view of the rear disc brakes-Mazda6, shown, Mazdaspeed6 models similar

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

    Wheels
     
    Parking brake cable clip
     
    Caliper brake hose bolt
     
    Caliper brake hose
     
    Caliper mounting bolts and the caliper
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Torque the caliper mounting bolts to 27-36 ft. lbs. (37-49 Nm) on Mazda6models, or 16-23 ft. lbs. (21-31 Nm) on Mazdaspeed6 models.
     
    Brake hose and pipe and tighten to 16-21 ft. lbs. (21-29 Nm).
     
    Parking brake cable clip and 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. Inspect the parking brake lever stroke and brake drag and adjust as necessary.
  4.  

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

    Wheels
     
    Parking brake cable from the cable bracket and the operating lever
     
    Flexible brake line from the caliper assembly
     

  4.  
  5. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the caliper piston inward (turn until it stops).

    Caliper mounting bolts
     
    Caliper
     

  6.  

To install:

  1. Install or connect the following:

    Caliper. Torque the caliper mount bolts to 26-28 ft. lbs. (35-39 Nm).
     
    Brake hose. Torque the line bolt to 16-22 ft. lbs. (22-30 Nm).
     
    Parking brake cable
     

  2.  
  3. Install the wheels and bleed the brake system.

    Click image to see an enlarged view

    Fig. Exploded view of rear brake systems-Protégé with disc brakes

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the wheels. Loosen the parking brake cable adjustment from inside the vehicle.
  4.  
  5. Remove or disconnect the following:

    Parking brake cable from the cable bracket and the operating lever
     
    Flexible brake line from the caliper assembly
     
    Caliper upper mounting bolt and pivot the caliper downward. Slide the caliper off of the guide pinch
     
    Caliper
     

  6.  

To install:

  1. Lubricate the caliper pin and slide the caliper onto the guide pinch Pivot the caliper over the brake pads.
  2.  
  3. Install or connect the following:

    Brake hose to the caliper and tighten the hose nut to 16-21 ft. lbs. (22-29 Nm)
     
    Upper caliper mounting bolt and tighten the bolt to 26-28 ft. lbs. (35-39 Nm)
     
    Parking brake cable to the cable bracket and the operating lever
     

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

    Click image to see an enlarged view

    Fig. Rear disc brakes-626

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Loosen the parking brake cable adjustment from inside the vehicle.
  4.  
  5. Remove or disconnect the following:

    Wheels
     
    Parking brake cable from the cable bracket and the operating lever
     
    Flexible brake line from the caliper assembly
     
    Cover for the manual adjustment gear. Insert an Allen wrench and turn counterclockwise to retract the caliper piston.
     
    Caliper mounting bolts and remove the caliper from the vehicle
     

  6.  

To install:

  1. Install or connect the following:

    Caliper and install the mounting bolts. Tighten the upper bolt to 33-36 ft. lbs. (45-49 Nm), and the lower bolt to 26-28 ft. lbs. (35-39 Nm).
     

  2.  
  3. Turn the manual adjustment gear clockwise to return the caliper until the brake pads just touch the disc, then turn counterclockwise 1 / 3 of a turn. Replace the cover.
  4.  
  5. After replacing the washers, connect the brake hose to the caliper. Tighten the hose nut to 16-21 ft. lbs. (22-29 Nm).
  6.  
  7. Connect the parking brake cable to the cable bracket and the operating lever.
  8.  
  9. Bleed the brake system and adjust the parking brake.
  10.  
  11. Install the wheels.

    Click image to see an enlarged view

    Fig. Rear disc brakes-Miata

  12.  

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

    Wheels
     
    Brake hose
     
    Caliper bracket mounting bolts and remove the caliper
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Torque the caliper mounting bolts to 12-17 ft. lbs. (16-23 Nm).
     
    Brake hose and pipe and tighten to 16-21 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. Rear disc brakes-Millenia

     

  2.  



Click image to see an enlarged view

Fig. Exploded view of the rear disc brakes-Mazda 6

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

    Wheels
     
    Parking brake cable clip
     
    Caliper brake hose bolt
     
    Caliper brake hose
     
    Caliper mounting bolts and the caliper
     

  4.  

To install:

  1. Install or connect the following:

    Caliper. Torque the caliper mounting bolts to 27-36 ft. lbs. (37-49 Nm).
     
    Brake hose and pipe and tighten to 16-21 ft. lbs. (21-29 Nm).
     
    Parking brake cable clip and 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. Inspect the parking brake lever stroke and brake drag and adjust as necessary.
  4.  

 
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