Mazda Trucks 1987-1993 Repair Guide

Caliper

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REMOVAL & INSTALLATION



Pickups and MPV

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Before disconnecting the brake hose at the caliper, clean any dirt or debris from the hose and banjo bolt connection using a wire brush



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Fig. Fig. 2: Remove the banjo bolt from the caliper connection. Be careful not to lose the crush washer that is located between the brake hose and banjo bolt



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Fig. Fig. 3: Be careful not to lose the crush washer that is located between the caliper and the hose fitting. Note that the two crush washers at the brake hose fitting are of different sizes and must not be mixed up



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Fig. Fig. 4: Inspect the condition of the caliper sliding bolt rubber boots and replace if necessary

  1. Raise and safely support the vehicle. Remove the wheel and tire assembly.
  2.  
  3. Remove the banjo bolt and disconnect the brake hose from the caliper. Plug the hose to prevent fluid leakage.
  4.  
  5. On pickups, remove the caliper mounting bolt and pivot the caliper about the mounting pin and off of the brake rotor. Remove the caliper from the pin.
  6.  
  7. On MPV, remove the caliper mounting bolts and remove the caliper.
  8.  
  9. To install, place the caliper in position and secure the mounting bolts following the reverse order of removal. Lubricate the caliper mounting bolts or bolt and pin prior to installation.
  10.  
  11. Tighten the caliper mounting bolt(s) to 23-30 ft. lbs. (31-41 Nm) on pickups; 61-69 ft. lbs. (83-93 Nm) on MPV. Bleed the brake system.
  12.  

Navajo

See Figure 5

  1. Siphon part of the brake fluid out of the master cylinder to avoid overflow when the caliper piston is pressed into the caliper bore.
  2.  
  3. Raise the vehicle and support it safely. Remove the wheel and tire assembly.
  4.  



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Fig. Fig. 5: Use a C-clamp to push the caliper piston back into the bore slightly before removing the caliper

  1. Position an 8 inch (203mm) C-clamp on the caliper and tighten the clamp to move the caliper piston into the bore approximately 1 / 8 inch (3mm). Avoid clamp contact with the outer shoe spring clip. Remove the clamp.
  2.  

Do not pry the piston away from the rotor.

  1. Clean excess dirt from the pin tab area.
  2.  
  3. Using a 1 / 4 inch drive socket, 3 / 8 inch deep and a light hammer, tap the upper caliper pin towards the outboard side until the pin tabs pass the spindle face.
  4.  
  5. Place one end of a 1/6 inch (11mm) diameter punch against the end of the caliper pin and tap the pin out of the caliper slide groove.
  6.  
  7. Repeat the procedure to remove the lower caliper pin.
  8.  
  9. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor.
  10.  

To install:
  1. Make sure the caliper mounting surfaces are free of dirt. Lubricate the caliper grooves with disc brake caliper grease and install the caliper.
  2.  
  3. From the caliper outboard side, position the pin between the caliper and spindle grooves. The pin must be positioned so the tabs will be installed against the spindle outer face.
  4.  
  5. Tap the pin on the outboard end with a hammer until the retention tabs on the sides of the pin contact the spindle face.
  6.  
  7. Repeat the procedure to install the lower pin.
  8.  

During installation, do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens, it will be necessary to tap the other end of the caliper pin until the tabs snap in place. The tabs on each end of the pin must be free to catch on the spindle face.

  1. Connect the brake hose to the caliper. Bleed the brake system.
  2.  
  3. Install the wheel and tire assembly and lower the vehicle. Check the brake fluid level and check the brakes for proper operation.
  4.  

OVERHAUL



See Figures 6, 7, 8, 9, 10, 11, 12 and 13

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  



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Fig. Fig. 6: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Fig. 7: Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



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Fig. Fig. 8: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



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Fig. Fig. 9: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 10: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



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Fig. Fig. 11: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



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Fig. Fig. 12: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



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Fig. Fig. 13: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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