MAZDA 626 1987 Workshop Manual

REAR DISC BRAKE 1 1
REMOVAL
1. Loosen the wheel lug nuts.
2. Release the parking brakes.
3. Jack up the rear of the vehicle and support it with safety stands.
4. Remove the wheels.
5. Remove in the sequence shown in the figure.
Warning Asbestos dust is a health hazard. Do not blow away brake dust with compressed air.
Caution
Brake fluid will damage painted surfaces. If it does get on a painted surface, wipe it off
immediately.
76G11X-084
1. Parking brake cable
2. Flexible hose
3. Caliper assembly
4. V-spring
5. Pad and shim
6. Guide plate
7. Mounting support
8. Disc plate
(Refer to section 9)
11—49

1 1 REAR DISC BRAKE
DISASSEMBLY AND ASSEMBLY
1. Disassemble the caliper in the sequence shown in the figure, referring to disassembly note for spe-
cially marked parts.
2. Inspect all parts, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
76G11X-0B5
1. Guide pin
2. Pin boot
3. Bushing
4. Retaining ring
5. Dust seal
6. Piston
7. Piston seal
8. Snap ring
9. Adjuster spindle
10. Stopper
11. O-ring
12. Connecting link
13. Return spring
14. Operating lever
15. Boot
16. Boot clip
17. Needle bearing
18. Cable braket
Disassembly Note
Piston
Remove the piston with the SST.
Note
The piston can be removed by turning the SST
counterclockwise.
86U11X-092
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REAR DISC BRAKE 1 1
86U11X-093
86U11X-094
86U11X-095
Piston seal
Remove the piston seal with the SST.
Needle bearing
1. Secure the caliper in a vise.
Caution
Insert a soft, protective material (such as cop-
per plates) in the jaws of the vise.
2. Remove the needle bearing from the caliper with
the SST.
Inspection Note
Check the following and repair or replace any faulty
parts.
1. Cylinder and piston for wear and rust
2. Caliper body for damage and cracks
3. Sleeve bolt and sleeve for damage and wear
4. Guide pin for damage and rust
5. Adjuster spindle threads for damage
Assembly Note
Application of grease
Before assembly, apply the grease supplied in the
seal kit to the parts indicated by the arrows.
Orange grease
White grease
Red grease
86U11X096
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1 1 REAR DISC BRAKE
86U11X-097
86U11X-098
86U11X-099
Needle bearing
1. Align the needle bearing hole with the caliper hole,
and set the needle bearing in the caliper.
2. Press the needle bearing into the caliper with the
SST until the SST bottoms against the caliper.
Connecting link
Install the connecting link into the operating lever.
Adjuster spindle
1. Assemble the adjuster spindle and the stopper.
2. Install the adjuster and stopper straight into the cal-
iper cylinder with the two stopper pins fit into the
caliper.
3. Install the snap ring.
86U11X-100
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REAR DISC BRAKE 1 1
86U11X-101
4. Move the operating lever and check that the ad-
juster spindle moves smoothly.
Piston
1. Clean the piston.
2. Install the dust seal in the piston groove.
3. Turn the piston into the caliper cylinder while rotat-
ing the SST clockwise.
Note
Turn the piston in fully, and align the piston
grooves as shown in the illustration.
4. Fit the dust seal into the caliper cylinder.
87U11X-102
11—53

1 1 REAR DISC BRAKE
INSPECTION
Check the following and replace or repair any faulty
parts.
Disc Pad
1. Oil or grease on facing
2. Abnormal wear or cracks
3. Deterioration or heat damage
4. Remaining lining thickness
Thickness: 1 mm (0.04 in) min.
76G11X-086
Disc Plate
1. Runout
Runout: 0.1 mm (0.004 in) max.
Caution
a) There must be no wheel bearing looseness.
b) Measure at the outer edge of the disc plate
surface.
86U11X-104
2. Wear or damage
Thickness
Standard: 10 mm (0.39 in)
Minimum: 8 mm (0.31 in)
86U11X-105
11—54

REAR DISC BRAKE 1 1
INSTALLATION
1. Install in the reverse order of removal, referring to installation note for the specially marked parts.
2. Tighten all nuts and bolts to the specified torque, referring to torque specifications.
3. After installation:
(1) Add brake fluid and bleed air. (Refer to page 11—9.)
(2) Adjust the parking brake lever stroke. (Refer to page 11 —65.)
(3) Depress the brake pedal a few times and check that the rear brakes do not drag excessively
while the wheels are being rotated.
Note
Refer to page 11—47 for pad installation.
Torque specifications
1. Parking brake cable
Installation Note
Parking brake cable
Connect the parking brake cable end onto the oper-
ating lever; then fix it to the bracket by the locknut.
Caution
There must be no clearance between the ca-
ble end and the operating lever.
86U11X-107
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1 1 REAR DRUM BRAKE
REAR DRUM BRAKE
REMOVAL
1. Loosen the wheel lug nuts.
2. Release the parking brakes.
3. Jack up the rear of the vehicle and support it with safety stands.
4. Remove the wheels.
5. Remove in the sequence shown in the figure, referring to removal note for the specially marked parts.
Caution
Do not damage the wheel cylinder dust boots when removing the brake shoes.
86U11X-108
1. Hub cap
2. Locknut
3. Brake drum
4. Parking brake cable
5. Return spring
6. Dust cover
7. Return spring (upper)
8. Hold pin and spring
9. Brake shoe (leading side)
10. Return spring (lower)
11. Anti-rattle spring
12. Hold pin and spring
13. Brake shoe (trailing side)
14. Operating lever assembly
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REAR DRUM BRAKE 1 1
15. Brake pipe
16. Wheel cylinder assembly
86U11X-109
17. Gasket
18. Backing plate
Removal Note
Locknut
Uncrimp the locknut, and remove it.
Caution Do not reuse the locknut.
86U11X-110
Brake drum
If the drum is difficult to remove, push the operating
lever stopper (at backing plate) upward to release the
operating lever and increase shoe clearance.
86U11X-111
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1 1 REAR DRUM BRAKE
Cleaning of drum brake assembly
Use a vacuum cleaner or equivalent to clean the
brake assembly
Warning
Asbestos dust is a health hazard. When clean-
ing the brake assembly, do not use compressed
air or a brush.
86U11X-112
Brake pipe
Disconnect the brake pipe with the SST.
Caution
Brake fluid will damage painted surfaces. If it
does get on a painted surface, wipe it off im-
mediately.
86U11X-113
11-58