Mazda Trucks 1994-1998 Repair Guide

Brake Pads

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REMOVAL & INSTALLATION



Navajo and 1994 B Series Pick-up Models

See Figures 1 through 13


CAUTION
Always replace disc brake pad assemblies on an axle. Never service one wheel only.

Mazda recommends that new caliper pins be installed whenever the caliper is removed from the steering knuckle.


CAUTION
Older brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. To avoid fluid overflow when the caliper piston is pressed into the caliper cylinder bores, remove or siphon part of the brake fluid out of the master cylinder reservoir (connected to the front disc brakes). Discard the removed fluid.
  2.  
  3. Loosen the wheel lug nuts.
  4.  
  5. Raise the vehicle and install jackstands. Remove a front wheel and tire assembly.
  6.  
  7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp slightly to push the caliper piston in its bore. This will ease caliper removal from the rotor. Remove the clamp.
  8.  

Do not use a screwdriver or similar tool to pry piston away from the rotor.

  1. Remove the upper caliper retaining pin as follows:
    1. Place one end of a punch, 1 / 2 in. (13mm) or smaller, against the end of the caliper pin and drive the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or other edged tool to help drive out the caliper pin as the V-grooves may be damage.
    2.  

  2.  
  3. Repeat the procedure in Step 4 for the lower caliper pin.
  4.  



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Fig. Fig. 1: Before beginning the brake pad procedure, remove some fluid from the master cylinder



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Fig. Fig. 2: Use a hammer and punch, and drive the caliper pin out from between the caliper and its mount



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Fig. Fig. 3: Pull the out from behind the caliper. Repeat the procedure for the lower pin

  1. Remove the caliper from the rotor.
  2.  
  3. Remove the outer pad. Remove the anti-rattle clips and remove the inner pad.
  4.  
  5. Place the inner pads friction material against the caliper piston and assemble the C-clamp to the caliper again. Tighten the clamp until the caliper piston is fully seated into its bore.
  6.  



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Fig. Fig. 4: Slide the caliper assembly off of the rotor



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Fig. Fig. 5: Holding the caliper as shown, press down then slide the pad out to remove it from the caliper



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Fig. Fig. 6: Remove the outer brake pad from the caliper



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Fig. Fig. 7: If necessary, support the caliper by a length of wire from the frame. Never let it hang by the hose



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Fig. Fig. 8: Finally, remove the inner brake pad from the steering knuckle assembly



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Fig. Fig. 9: Place the inner pad-s friction material against the caliper piston and press it in with a C-clamp



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Fig. Fig. 10: Ensure that the anti-rattle clip is installed as shown on the inner pad



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Fig. Fig. 11: View of a correctly installed outer pad



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Fig. Fig. 12: Ensure that the tang is driven flush to the caliper mount



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Fig. Fig. 13: After installing the pins, ensure that the tangs are free to contact either side of the caliper mount

To install:
  1. Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are positioned properly and the clip is fully seated.
  2.  
  3. Position the inner pads and anti-rattle clip in the abutment with the anti-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position.
  4.  
  5. Install the outer pad, making sure the torque buttons on the pad spring clip are seated solidly in the matching holes in the caliper.
  6.  
  7. Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate the caliper grooves with Disc Brake Caliper Grease. Install new caliper pins, making sure the pins are installed with the tang in position as illustrated. The pin must be installed with the lead tang in first, the bolt head facing outward (if equipped) and the pin positioned as shown. Position the lead tang in the V-slot mounting surface and drive in the caliper until the drive tang is flush with the caliper assembly. Install the nut (if equipped) and tighten to 32-47 inch lbs.
  8.  
  9. Install the wheel and tire assembly.
  10.  
  11. Remove the jackstands and lower the vehicle. Torque the lug nuts to 100 ft. lbs. (135 Nm).
  12.  

The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the brake pedal until it feels firm.

  1. Check the brake fluid level and fill as necessary. Check the brakes for proper operation before driving the vehicle.
  2.  

1995-98 B Series Pick-up Models

See Figures 14, 15 and 16



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Fig. Fig. 14: Exploded view of the 4x4 navajo and 1994-97 B Series Pick-up front brake caliper assembly-4x2 similar



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Fig. Fig. 15: Exploded view of the 1998 4x4 B Series Pick-up front brake caliper assembly-4x2 models similar



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Fig. Fig. 16: Use a C-clamp to slightly press in the caliper piston to aid removal


CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. To avoid fluid overflow when the caliper piston is pressed into the caliper cylinder bores, remove or siphon part of the brake fluid out of the master cylinder reservoir (connected to the front disc brakes). Discard the removed fluid.
  2.  
  3. Loosen the wheel lug nuts.
  4.  
  5. Raise and safely support the front of the vehicle. Remove the wheel.
  6.  
  7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores. Remove the clamp.
  8.  
  9. Remove the two caliper slide pin bolts and lift the caliper from the anchor plate.
  10.  

Use care to retain as much of the original caliper slide pin grease as possible.

  1. Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang by the brake hose.
  2.  
  3. Remove the brake pads and, if necessary, the anti-rattle clips from the anchor plate.
  4.  
  5. Remove the shims, if any, from the brake pads for re-use.
  6.  

To install:
  1. If removed, install the anti-rattle clips.
  2.  
  3. Install the brake pads to the anchor plate.
  4.  
  5. Position the caliper over the brake pads and align the slide pin mounting holes.
  6.  
  7. Install the slide pin bolts and tighten them to 21-26 ft. lbs. (28-36 Nm).
  8.  
  9. Install the wheel and snug the lug nuts.
  10.  
  11. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
  12.  

The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the brake pedal until it feels firm.

  1. Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the pedal feels firm before operating the vehicle.
  2.  

MPV Models

See Figures 17 through 23



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Fig. Fig. 17: The bottom end of the inner brake pad is equipped with a pad thickness sensor, which makes a squealing noise to alert you that the pads must be changed



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Fig. Fig. 18: When removing the disc brake pads, you only have to remove the bottom caliper slide bolts



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Fig. Fig. 19: After removing the bottom sliding bolt, swing up and support the caliper with a strong piece of wire. Then remove the inner and outer disc brake pads



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Fig. Fig. 20: Using a brake caliper piston and compressor tool and an old brake pad, push the pistons into the bore. If equipped with dual piston calipers, it may be necessary to alternate the tool back and forth between the pistons (arrows)



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Fig. Fig. 21: If necessary, remove and clean, or replace, the four anti-rattle clips located in the caliper on the ends of each brake pad



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Fig. Fig. 22: Before installing the pads and caliper, clean the anti-rattle clips with a brush



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Fig. Fig. 23: Before installing the sliding caliper bolts, clean them and then lubricate them with brake grease

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the lower lock pin bolt from the caliper.
  6.  
  7. Rotate the caliper upward and support the caliper with a strong piece of wire. Rremove the brake pads, shims, guide plates and if equipped, the springs.
  8.  
  9. Remove the master cylinder reservoir cap and remove about half of the fluid from the reservoir.
  10.  
  11. Using a large C-clamp and piece of wood, or a brake caliper piston and compressor tool and an old brake pad, compress the caliper piston(s) until they bottom in their bores.
  12.  

To install:
  1. Install the shims, guide plates, new pads and if removed, the springs. If necessary, replace, the four anti-rattle clips located in the caliper on the ends of each brake pad
  2.  
  3. Reposition the caliper and install the lock pin bolt. Tighten the lockbolt to:
  4.  



Front caliper: 62-68 ft. lbs. (84-93 Nm)
 
Rear caliper: 28-36 ft. lbs. (38-49 Nm)
 

  1. Install the wheels, lower the vehicle, refill the master cylinder and depress the brake pedal a few times to restore pressure. Bleed the system if required.
  2.  

INSPECTION



See Figure 24



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Fig. Fig. 24: If inspecting the thickness of the brake pads, the pads are visible through the two openings in the caliper unit

Replace the disc brake pads when the pad thickness is at the minimum thickness recommended by Mazda Motor Co., or at the minimum allowed by the applicable state or local motor vehicle inspection code. Pad thickness may be checked by removing the wheel and looking through the inspection port in the caliper assembly.

Replace the disc brake pads when the pad thickness is at the following minimum thicknesses:



Navajo and 1994 B Series Pick-up: 0.12 inch (3.0mm)
 
1995-97 B Series Pick-up: 0.05 inch (1.5mm)
 
1998 B Series Pick-up: 0.10 inch (2.5mm)
 
MPV: 0.08 inch (2.0mm)-front / 0.04 inch (1.0mm)-rear
 

 
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