Mazda Trucks 1972-1986 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



  1. Follow the preceding procedure for removing the brake pads.
  2.  
  3. Disconnect the brake line at the caliper and plug the line.
  4.  
  5. Installation is the reverse of removal. Bleed the brakes.
  6.  

OVERHAUL



See Figures 1, 2, 3, 4 and 5

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Fig. Fig. 1: Exploded view of the caliper components



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Fig. Fig. 2: Use compressed air to force the piston out of the caliper housinga block of wood is positioned to catch the piston



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Fig. Fig. 3: Pry out the dust seal



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Fig. Fig. 4: Piston removed from the caliper



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Fig. Fig. 5: Exploded view of the piston componentsinset shows location of the color coded grease application points

  1. Remove the caliper.
  2.  
  3. Place a thin piece of wood in the caliper, in front of the piston. Apply enough compressed air through the brake line inlet hole to force the piston out of the caliper. Don't try to catch the piston with your fingers. A set of mashed fingers will result. It's also a good idea to wear safety glasses, as a spray of brake fluid will often result. If the piston is seized, try tapping around the caliper while applying pressure. If that doesn't work, fill the caliper with a rust dissolving agent such as Liquid Wrench or WD-40 and let it stand for a while.
  4.  
  5. Discard all rubber parts.
  6.  
  7. Remove the bleeder screw.
  8.  
  9. Clean all parts in clean brake fluid. Inspect the piston and bore for any signs of wear, damage or heat discoloration. Minor damage can be corrected with light polishing using a crocus cloth.
  10.  
  11. Rebuilding kits are equipped with two kinds of grease, color coded orange and red. See the illustration for application details. Install a new seal, lubricated with clean brake fluid, on the piston. Be sure that the seal is not twisted!
  12.  
  13. Lubricate the piston and bore with clean brake fluid and insert the piston in the bore.
  14.  
  15. Install a new dust boot and retainer.
  16.  
  17. Install the bleeder screw.
  18.  
  19. Install the caliper in reverse of removal.
  20.  

 
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