Mazda Car 2002-04

Brake Disc (Rotor)

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Removal & Installation





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
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Rotor
     
    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 some of the brake fluid from the master cylinder reservoir.
  4.  
  5. Loosen the parking brake cable adjustment from inside the vehicle.
  6.  
  7. Remove or disconnect the following:

    Wheels.
     
    Parking brake cable from the cable bracket and the operating lever
     
    Caliper mounting bolts and the caliper
     
    Brake pads and spring clips from the caliper support
     
    Mounting support bolts and support
     
    Guide plate

    Click image to see an enlarged view

    Fig. Location of the manual adjustment gear on the rear caliper-626

     

  8.  

To install:

  1. Turn the manual adjustment gear counterclockwise using an Allen wrench to retract the caliper until it stops.
  2.  
  3. Install or connect the following:

    Mounting support and bolts. Tighten the bolts to 34-49 ft. lbs. (46-66 Nm)
     
    Guide plate
     
    Brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.
     

  4.  
  5. Turn the adjustment gear clockwise until the pads start to touch the rotor and back of the gear 1 / 3 turn.


  6.  
  7. Lubricate the top caliper mounting bolt, then tighten the bolt to 26-28 ft. lbs. (35-39 Nm). Attach the parking brake cable to the operating lever.
  8.  
  9. Adjust the parking brake cable, as required.
  10.  
  11. Install the wheels.
  12.  
  13. Test the brakes for proper operation.
  14.  

  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
     
    Guide plate
     
    Mounting support bolts and support
     

  6.  

To install:

  1. Install or connect the following:

    Guide plate
     
    Mounting support and bolts. Tighten the bolts to 37-50 ft. lbs. (50-68 Nm)
     
    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
     
    Guide plate
     
    Mounting support bolts and support
     
    Back off the parking brake shoes, by removing the service plug at the back of the plate, insert a suitable tool into the hole and turn the adjuster clockwise.
     

  4.  

To install:

  1. Install or connect the following:

    Rotor
     

  2.  
  3. Remove any rust or grime on the contact face of the disc plate and wheel hub.
  4.  
  5. Install the disc plate and align the marks made before removal.
  6.  
  7. After installing the disc plate, adjust the parking brake shoe clearance as follows:
    1. Insert a screwdriver into the hole and turn the adjuster in the direction of the arrow as shown in the illustration until the disc plate locks.
    2.  
    3. Set the shoe clearance to approx. 0.013 in. {0.34 mm} by turning the adjuster 3 to 5 notches in the opposite direction of the arrow marked on the disc plate.
    4.  
    5. Rotate the disc plate by hand, and verify that the brakes do not drag.
    6.  
    7. Install the disc plate service plug.

      Click image to see an enlarged view

      Fig. Exploded view of the parking brake shoe assembly-Millenia



      Click image to see an enlarged view

      Fig. Install the operating lever with the shoe facing towards the front of the vehicle-Millenia



      Click image to see an enlarged view

      Fig. shoe clearance to approx. 0.013 in. {0.34 mm} by turning the adjuster 3 to 5 notches in the opposite direction of the arrow as shown-Millenia

    8.  

  8.  
  9. Install or connect the following:

    Guide plate
     
    Mounting support and bolts. Tighten the bolts to 37-50 ft. lbs. (50-68 Nm)
     
    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

     

  10.  

  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
     
    Guide plate
     
    Mounting support bolts and support
     

  6.  

To install:

  1. Install or connect the following:

    Guide plate
     
    Mounting support and bolts. Tighten the bolts to 34-49 ft. lbs. (46-66 Nm)
     
    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 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
     
    Rotor
     

  4.  

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 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.  
  5. Before servicing the vehicle, refer to the precautions section.
    NOTE
    Refer the exploded view illustration for component locations and if applicable, their retainer torque specifications.

  6.  
  7. Disconnect the parking brake cable.
  8.  
  9. Remove the upper caliper bolt and pivot the caliper downwards.
  10.  
  11. Remove the disc pads and shims.
  12.  
  13. Remove the caliper mount.
  14.  
  15. Remove the rotor.
  16.  

To install:

  1. Clean the exposed area of the piston.
  2.  
  3. Install the caliper mount. Tighten the bolts 36-50 ft. lbs (49-68 Nm).
  4.  
  5. Rotate the piston clockwise slowly using the tool shown to push the piston completely until the piston grooves are in the position shown in the figure.
  6.  
  7. Install the components in the reverse order of removal. Tighten the caliper bolts to 20-25 Nm (14-18 ft. lbs.).
  8.  
  9. Install the parking brake cable. After installation the parking brake cable, verify that the operating lever returns to the stopper nut with the parking brake lever released.
  10.  
  11. Depress the brake pedal a few times and verify that the brakes do not drag
  12.  



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
     
    Rotor
     

  4.  

To install:

  1. Install or connect the following:

    Rotor
     
    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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