brake MAZDA PROTEGE 1992 Service Manual

INDEX
1. Front axle 3. Joint shaft (BP DOHC)
Preinspection ............................. M-l 8
............................. page M- 5 Preinspection page
Removal / Installation page M- 5 Removal / Installation
.................
................. page M-18
Disassembly / Inspection / Overhaul ....................................
page M-20
Assembly ................................. page M- 7 4. Drive shaft
2. Rear axle Removal / Installation
................. page M-22
[Drum brake type] Overhaul .................................... page M-25
Preinspection .............................
page M-l 1
Removal / Inspection /
Installation.. .............................. page
M-l 1
Disassembly I Assembly ............ page M-l 3
[Disc brake type]
Preinspection ............................. page M-14
Removal / Inspection /
Installation ................................ page
M-14
Disassembly / Assembly ............
page M-i 5
M-2

FRONT AXLE M
WHEEL HUB, STEERING KNUCKLE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly and disc plate.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Removal / Installation
d Maximum wheel bearing play: 0.05mm (0.002 in)
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, check the front wheel alignment. (Refer to Section R.)
SERVIC\E, SECTION R

7 93--12? W.-L%” COTiER PIN, REPLACE
(9.5-12.9, 69-S
39-54
(4.0-5.6, 29-40) 39-64 ’ 236-319 (24.0-32.5, 174-235)
(4.4-6.0, 32-43)
66-67)
N.m (m-kg, it-lb)
23UOMX-006
1. Wheel and tire
2. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
3. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
4. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
5. Tie rod end
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M- 6 6. Lower ball joint
7. Knuckle, wheel hub, and dust cover
Inspect wheel hub for cracks and damage
Inspect knuckle spindle for cracks and
damage
Inspect dust cover for damage and dis-
tortion
Disassembly / Inspection I
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page M- 7
M-5

M FRONT AXLE, REAR AXLE
03UOMX-0
OII seal
Caution
l Use a new oil seal, and apply grease to the lip of
the seal.
l Install the oil seal flush with the knuckle.
1. Install the new oil seal with the SST.
REAR AXLE
PREPARATION
SST
I
I
49 0259 7708 For
removal and
Wrench, flare nut
w installation of
brake pipe
23lJOMX.011
M-10

REAR AXLE M
L.3”“I”lh-” I
Removal / Inspection / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation, bleed the brake system, adjust the parking brake lever stroke (Refer to Section P.) and
DRUM BRAKE TYPE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Position a dial indicator against the brake drum. Push and
pull the rear brake assembly by hand in the axial direction
and measure the wheel bearing play.
3. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
Maximum wheel bearing play: 0.05mm (0.002 in)
66-l 17 (6.7-l 1.9, 63-66)
45-59
(4.6:6.0, 33-43)
check the rear wheel alignment (Refer to Section R.)
SEiWICE, SECTION R /
I
GA
19-26 (1.9-2.6, 14-19)
177-235
(16.0-24.0, 130-174) d
REPLACE REPLACE
(9.0-12.0,
65-67)
N.m (m-kg, ft-lb)
7RI ImAX-ni
J 3
1. Wheel and tire
2. Hub cap
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 2
4. Brake drum
5. Hub bearing assembly
Inspect for cracks and damage
Disassembly I Assembly . . . . . . . . . . . . page M-l 3 6. Parking brake cable
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P
7. Brake pipe
Removal Note .,.......................... page M-12
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-l 2
8. Rear brake assembly
Service ,,........................................ Section P
9. Rear spindle
Inspect for cracks and damage
M-l 1

M REAR AXLE
!O
03UOMX-01 0
0.5mm
19
Removal note
Brake pipe
Caution
l After disconnecting the brake pipe, plug it to avoid
fluid leakage.
1. Disconnect the brake pipe with the SST.
lnstallatlon note
Brake pipe
1. Tighten the brake pipe with the SST.
Tightening torque:
13-22 N*m (1.3-2.2 m-kg, 9.4-16 ft-lb)
Locknut
1. Install a new locknut and stake it, as shown.
Tightening torque:
177-236 Narn (16-24 m-kg, 130-l 74 ft-lb)
M-12

M REAR AXLE
DISC BRAKE TYPE
Preinspection
Wheel bearing play
1. Remove the wheel and tire.
2. Remove the brake caliper assembly.
3. Position a dial indicator against the wheel hub. Push and
pull the wheel hub by hand in the axial direction and meas-
ure the wheel bearing play.
4. If the bearing play exceeds specification, check and adjust
the locknut torque or replace the wheel bearing if necessary.
-I 5 Maximum wheel bearing play: 0.05mm (0.002 in)
Removal / Inspection / Installation
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
4. After installation. check the rear wheel alianment (Refer to Section R.)
45-61
(4.6-6.2, 33-45)
-118
-12.0,
-87)
REPLACE
16-23
(1.6-2.3, 12-17)
N-m (m-kg, ft-lb]
311 InMY-nif4
1. Wheel and tire
2. Hub cap
3. Locknut
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . page M-15
4. Brake caliper assembly
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~ Section P
5. Disc plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section P 6. Hub bearing assembly
Inspect for cracks and damage
Disassembly I Assembly . . . . . . . . . . . . page M-l 5
7. Dust cover
8. Rear spindle
Inspect for cracks and damage
M-14

P
BRAKING SYSTEM
INDEX ......................................................
OUTLINE .................................................. ;I g
SPECIFICATIONS .................................... P- 3
CONVENTIONAL BRAKING SYSTEM.. ......... P- 4
PREPARATION ....................................... P- 4
TROUBLESHOOTING GUIDE .................... P- 5
AIR BLEEDING .......................................
BRAKE HYDRAULIC LINE.. -
...................... F- t
BRAKE FLUID ........................................
BRAKE PEDAL ....................................... ;I ;
MASTER CYLINDER ................................ P-l 0
POWER BRAKE UNIT .............................. P-13
DUAL PROPORTIONING VALVE.. .............. P-l 6
FRONT BRAKE (DISC) ............................. P-16
CALIPER ............................................... P-21
REAR BRAKE (DISC) ............................... P-23
CALIPER ............................................... P-26
REAR BRAKE (DRUM) ............................. P-28
WHEEL CYLINDER .................................. P-30
PARKING BRAKE SYSTEM ........................ P-31
TROUBLESHOOTING GUIDE .................... P-31
PARKING BRAKE SHOE .......................... P-31
PARKING BRAKE (LEVER TYPE) ............... P-31
PARKING BRAKE CABLE.. ....................... P-32
PARKING BRAKE LEVER ......................... P-33
13UOPX-001

P INDEX
NDEX
LEVER STROKE (WHEN PULLED WITH A FORCE OF 98 N [lo kg, 22 lb])
FMVSS 116, DOT-3,
SAE J1703 OTCHES
1. Brake hydraulic line
Inspection / Removal /
Installation.. ............................... page P- 6
2. Brake pedal
Inspection (on-vehicle).
............... page P- 8
Removal / Inspection /
Installation ................................. page P-l 0
3. Master cylinder
Removal I installation.. ................ page P-10
Disassembly / Inspection /
Assembly .................................. page P-12
4. Power brake unit
Inspection (on-vehicle). ............... page P-l 3
Removal I Installation.. ................ page P-16
5. Dual proportioning valve
Inspection
................................... page P-l 6
Replacement.. ............................. page P-l 7
6. Front brake (disc)
Inspection (on-vehicle). ............... page P-l 8
Replacement.. .............................
page P-l 8
Removal / installation.. ................ page P-l 9
Inspection ...................................
page P-20
7. Caliper
Disassembly I Inspection /
Assembly.. ................................ page P-21
P-2
8. Rear brake (disc)
23UOPX-008
Inspection (on-vehicle) . . . . . . . , , ., . . . . page P-23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-23
Removal / Installation . . . . . . . . . . . . . . . . . . page P-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-25
9. Caliper
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-26
10. Rear brake (drum)
Inspection (on-vehicle). . . . . . . . . . . . . . . . page P-28
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-28
11. Wheel cylinder
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-30
12. Parking brake (lever type)
Inspection (on-vehicle) . . . . . . . . . . . . . . . . page P-31
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-31
13. Parking brake cable
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-32
14. Parking brake lever
Removal / Inspection / --
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-33

OUTLINE
OUTLINE
SPECIFICATIONS
item Specifications
Brake pedal
Master cylinder
Front disc brake
Rear disc brake
Rear drum brake
Power brake unit
Braking force control device
Brake fluid Type Suspended
Pedal lever ratio
I 4.1
I
Max. stroke mm (in) 140 (5.51)
I
Type
Cylinder inner diameter mm (in)
Type
Cylinder bore mm (in)
Pad dimensions (area x thickness)
mm’ (in2) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness) Tandem (with level sensor)
22.22 (0.875)
Ventilated disc (integral)
53.97 (2.12)
13-in wheel: 3,800 (5.89)x 10 (0.39)
14-in wheel: 4,300 (6.66) x 10 (0.39)
13-in wheel: 235 x 22 (9.25 x 0.87)
14-in wheel: 257 x 22 (10.12 x 0.87)
We
I Solid disc (mounting support)
I
Cylinder bore mm (in)
I 30.2 (1.19)
I
Pad dimensions (area x thickness)
mm2 (in’) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness)
Type 2,600 x 8.0 (4.03 x 0.31)
251 x 9 (9.88 x 0.35)
Leading-trailing
Wheel cylinder inner diameter mm (in) 17.46 (0.687)
I
Lining dimensions mm (in)
(width x length x thickness) 35x192.0x4.5 (1.38x7.56x0.18)
I
Drum inner diameter mm (in) 200 (7.9)
I
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
@ : 214 (8.43) @ : 239 (9.41)
Dual proportioning valve
FMVSS 116: DOT-3, SAE: J1703
Type
Diameter
Type mm (in)
Parking brake
Type
Operation system Mechanical two rear wheel control
Center lever I
3 With BP SMTX, B6, @With BP 4EATX
I I
23UOPX-001
P-3

CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM
PREPARATION
SST
49 0259 770B
For 49 F043 001
For
removal of
adjustment of
Wrench, flare nut
w brake pipe Adjust gauge
piston-to-push
rod clearance
49 0208 701A
For 49 0221 600C For
removal of
installation of
Air-out tool, boot 471 piston seal
Expand tool, disc brake pads
brake (Front disc brake)
._’
P-4