Mazda

Brake Caliper

REMOVAL & INSTALLATION

Protege

FRONT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels.
3. Disconnect the flexible brake hose from the caliper.
4. Remove the disc pad retaining pins. Remove the brake pads.
5. Remove the upper and lower caliper bolts. Remove the caliper from the vehicle.

   To install:

6. Position the caliper on the brake disc. Install the caliper mounting bolts and tighten the bolts to 29–36 ft. lbs. (40–49 Nm).
7. Install the disc pads and retaining pins.
8. Replace the washers for the brake line. Connect the brake hose to the caliper and tighten the hose nut to 16–21 ft. lbs. (22–29 Nm).
9. Bleed the brake system.
10. Install the wheels.

REAR

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels.
3. Disconnect the parking brake cable from the cable bracket and the operating lever.
4. Disconnect the flexible brake line from the caliper assembly.
5. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the caliper piston inward (turn until it stops).
6. Remove the caliper mounting bolts. Remove the caliper from the vehicle.

   To install:

7. Install the caliper. Torque the caliper mount bolts to 34–44 ft. lbs. (46–60 Nm).
8. Install the brake hose. Torque the line bolt to 16–22 ft. lbs. (22–30 Nm).
9. Connect the parking brake cable.
10. Install the wheels and bleed the brake system.

    Fig. 1: Front disc brakes — Protégé

    Fig. 2: Rear disc brakes — Protégé

626 and MX6

FRONT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels.
3. Disconnect the flexible brake hose from the caliper.
4. Remove the lower caliper bolt and pivot the caliper upward. Slide the top of the caliper off of the top pin and remove it from the vehicle.

   To install:

5. Lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads.
6. Connect the brake hose to the caliper and tighten the hose nut to 16–21 ft. lbs. (22–29 Nm).
7. Install the caliper mounting bolt and tighten the bolt to 22–29 ft. lbs. (30–40 Nm).
8. Bleed the brake system and inspect the brake system for proper operation.
9. Install the wheels.

   Fig. 3: Front disc brakes — 626

REAR

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels. Loosen the parking brake cable adjustment from inside the vehicle.
3. Disconnect the parking brake cable from the cable bracket and the operating lever.
4. Disconnect the flexible brake line from the caliper assembly.
5. Remove the caliper upper mounting bolt and pivot the caliper downward. Slide the caliper off of the guide pin. Remove the caliper from the vehicle.

   To install:

6. Lubricate the caliper pin and slide the caliper onto the guide pin. Pivot the caliper over the brake pads.
7. Connect the brake hose to the caliper and tighten the hose nut to 16–21 ft. lbs. (22–29 Nm).
8. Install the upper caliper mounting bolt and tighten the bolt to 26–28 ft. lbs. (35–39 Nm).
9. Connect the parking brake cable to the cable bracket and the operating lever.
10. Bleed the brake system.
11. Install the wheels.

    Fig. 4: Rear disc brakes — 626

Miata

FRONT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels.
3. Disconnect the flexible brake hose from the caliper.
4. Remove the upper and lower caliper bolts. Remove the caliper from the vehicle.

   To install:

5. Position the caliper on the brake disc. Install the caliper mounting bolts and tighten the bolts to 36–51 ft. lbs. (49–69 Nm).
6. Replace the washers for the brake line. Connect the brake hose to the caliper and tighten the hose nut to 16–22 ft. lbs. (22–29 Nm).
7. Bleed the brake system and inspect the brake system for proper operation.
8. Install the wheels.

   Fig. 5: Front disc brakes — Miata

REAR

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Loosen the parking brake cable adjustment from inside the vehicle.
3. Remove the wheels.
4. Disconnect the parking brake cable from the cable bracket and the operating lever.
5. Disconnect the flexible brake line from the caliper assembly.
6. Remove the cover for the manual adjustment gear. Insert an Allen wrench and turn counterclockwise to retract the caliper piston.
7. Remove the caliper mounting bolts and remove the caliper from the vehicle.

   To install:

8. Position the caliper and install the mounting bolts. Tighten the upper bolt to 33–36 ft. lbs. (45–49 Nm), and the lower bolt to 25–29 ft. lbs. (34–39 Nm).
9. Turn the manual adjustment gear clockwise to return the caliper until the brake pads just touch the disc, then turn counterclockwise ¹⁄₃ of a turn. Replace the cover.
10. After replacing the washers, connect the brake hose to the caliper. Tighten the hose nut to 16–21 ft. lbs. (22–29 Nm).
11. Connect the parking brake cable to the cable bracket and the operating lever.
12. Bleed the brake system and adjust the parking brake.
13. Install the wheels.

    Fig. 6: Rear disc brakes — Miata

Millenia

FRONT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels.
3. Disconnect the brake hose and brake pipe.
4. Remove the caliper mounting bolts and remove the caliper.

   To install:

5. Install the caliper. Torque the caliper mounting bolts to 47–62 ft. lbs. (63–84 Nm).
6. Connect the brake hose and pipe. Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
7. Install the wheels.

   Fig. 7: Front disc brakes — Millenia

REAR

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the wheels.
3. Disconnect the brake hose.
4. Remove the caliper bracket mounting bolts and remove the caliper.

   To install:

5. Install the caliper. Torque the caliper mounting bolts to 12–17 ft. lbs. (16–23 Nm).
6. Connect the brake hose and pipe. Fill the master cylinder with clean brake fluid and bleed the hydraulic system.
7. Install the wheels.

   Fig. 8: Rear disc brakes — Millenia