Mazda Trucks 1994-1998 Repair Guide

Brake Rotor (Disc)

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REMOVAL & INSTALLATION



Navajo and B Series Pick-up Models
EXCEPT 1995-98 4-WHEEL DRIVE MODELS
  1. Loosen the wheel lug nuts.
  2.  
  3. Jack up the front of the vehicle and support on jackstands.
  4.  
  5. Remove the wheel and tire.
  6.  
  7. On 1994 models, remove the brake caliper assembly as described earlier in this Section, but do not disconnect the brake hose.
  8.  
  9. On 1995-98 models, remove the two anchor plate-to-steering knuckle bolts then slide the assembly off of the rotor.
  10.  
  11. Suspend the caliper assembly by a piece of wire. Do not allow it to hang by the brake hose.
  12.  
  13. Follow the procedure given under wheel bearing removal in Drive Train for models with manual and automatic locking hubs.
  14.  

New rotor assemblies come protected with an anti-rust coating which should be removed with denatured alcohol or degreaser. New hubs must be packed with EP wheel bearing grease.

  1. Installation is the reverse of the removal procedure.
  2.  

1995-98 4-WHEEL DRIVE MODELS
  1. Loosen the wheel lug nuts.
  2.  
  3. Jack up the front of the vehicle and support on jackstands.
  4.  
  5. Remove the wheel and tire.
  6.  
  7. Remove the two anchor plate-to-steering knuckle bolts then slide the assembly off of the rotor.
  8.  
  9. Grasp the rotor and pull it from the wheel hub. Some models may have a small retaining screw holding the rotor to the wheel hub, if so, remove the screw then pull the rotor off.
  10.  
  11. Installation is the reverse of the removal procedure.
  12.  

MPV Models

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Using a 17mm box wrench, remove the two brake caliper slide bolts



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Fig. Fig. 2: To remove the brake rotor, remove the two brake caliper mounting bolts using a 21mm socket and breaker bar, if necessary



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Fig. Fig. 3: Remove the caliper and pad assembly from the brake rotor ...



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Fig. Fig. 4: ... and suspend from the strut coil using a strong piece of wire



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Fig. Fig. 5: Pull the rotor unit off of the whhel hub/bearing


CAUTION
Brake pads 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. Raise and safely support the vehicle. Remove the wheel and tire assembly.
  2.  
  3. Remove the caliper and support it aside with mechanic's wire; do not let the caliper hang by the brake hose. Remove the disc brake pads and mounting support.
  4.  
  5. Remove the attaching screw and remove the rotor.
  6.  
  7. Inspect the rotor for scoring, wear and runout. Machine or replace as necessary.
  8.  
  9. If rotor replacement is necessary on pickup models, remove the attaching bolts and separate the rotor from the hub.
  10.  
  11. Installation is the reverse of removal.
  12.  

INSPECTION



See Figure 6



Click image to see an enlarged view

Fig. Fig. 6: Disc brake service limits-Navajo and B Series Pick-up rotor shown

  1. Inspect the rotor for cracks, grooves or waviness. Rotors that aren't too badly scored or grooved can be resurfaced by most automotive shops.
  2.  
  3. Measure the rotor thickness using a caliper gauge.
  4.  
  5. Minimum rotor thickness should be the following:

    Navajo and 1994-97 B Series Pick-up: 0.81 in. (20.5mm)
     
    1998 B Series Pick-up: 1.02 inch (26.0mm)
     
    MPV: 1.02 inch (26.0mm)-front / 0.63 inch (16.0mm)-rear
     

  6.  
  7. If refinishing exceeds that, the rotor will have to be replaced.
  8.  

 
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