Mazda Trucks 1994-1998 Repair Guide

Calipers

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See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the single piston caliper



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Fig. Fig. 2: Cross-sectional view of the dual piston caliper

REMOVAL & INSTALLATION



Navajo and B Series Pick-up Models

See Figures 3, 4 and 5

  1. Follow the procedures for pad removal earlier in this section.
  2.  



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Fig. Fig. 3: Loosen the brake hose-to-caliper retaining bolt ...

  1. Remove the brake hose-to-caliper attaching bolt.
  2.  



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Fig. Fig. 4: ... then remove it, along with the hose fitting and the sealing washers



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Fig. Fig. 5: Always discard the old sealing washers and use new ones when installing the caliper

  1. Discard the brass washers and plug the brake hose and caliper bolt hole.
  2.  
  3. On dual piston caliper models, and if necessary, remove the brake pad anchor plate by removing the two attaching screws from the back of the steering knuckle.
  4.  
  5. Inspect the caliper, piston and rubber seals/boots for damage and replace as necessary.
  6.  

To install:
  1. On dual piston calipers, and if removed, position the anchor plat to the steering knuckle and install the two retaining bolts. Use a threadlocking compound on the old bolts or install new bolts and tighten them to 73-97 ft. lbs. (98-132 Nm).
  2.  
  3. If it was necessary to remove the brake pads, install them to the anchor plate (dual piston) or caliper (single piston).
  4.  
  5. Install the caliper as instructed in the brake pad installation procedures.
  6.  

Always use new sealing washers when assembling the hose to the brake caliper.

  1. Place a new sealing washer on the brake hose bolt, slide the bolt through the hose fitting and install a second sealing washer to the bolt.
  2.  
  3. Position the hose/bolt to the caliper then tighten the bolt to 22-29 ft. lbs. (30-40 Nm).
  4.  
  5. Bleed the brake system. Check for leaks and proper operation before placing the vehicle into service.
  6.  

MPV Models

See Figures 6, 7, 8 and 9



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Fig. Fig. 6: 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. 7: 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. 8: 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. 9: 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. Remove the caliper mounting bolt and pivot the caliper about the mounting pin and off the brake rotor. Remove the caliper from the pin.
  6.  
  7. If installing the same caliper, inspect the condition of the caliper sliding bolt rubber boots and replace if necessary.
  8.  
  9. Installation is the reverse of the removal procedure. Lubricate the caliper mounting bolts or bolt and pin prior to installation.
  10.  
  11. Tighten the caliper mounting bolt(s) to:
  12.  



Front caliper: 61-69 ft. lbs. (83-93 Nm)
 
Rear caliper: 37-50 ft. lbs. (50-68 Nm)
 

  1. Bleed the brake system. Check for leaks and proper operation before placing the vehicle into service.
  2.  

OVERHAUL



See Figures 10 through 17

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.

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      Fig. Fig. 10: 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. 11: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



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Fig. Fig. 12: 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. 13: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 14: ... 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. 15: 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. 16: 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. 17: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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