Rear brake MAZDA 626 1987 Service Manual

TROUBLESHOOTING GUIDE 9
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Faulty operation of
driveshaft
Broken ball joint
Broken tri-pod joint
Worn or seized joint
Replace
Replace
Replace
9—31
9—35
9—31, 35
Abnormal noise from driveshaft Insufficient grease in joint or spline Excessive backlash on spline Worn joint
Add or replace
Replace
Replace
9—33, 36 9—31, 35 9-31, 35
Steering wheel pulls. (Steering wheel pulls toward either right or left side)
Bent steering linkage
Fatigued coil spring
Lower arm bushing worn or damaged Bent knuckle Bent lower arm or loose mounting Incorrect toe-in adjustment Improper tire air pressure Unevenly worn tires (left and right tires) Brake dragging
Refer to Section 10 Refer to Section 13 Refer to Section 13 Replace Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12 Refer to Section 11
9-11
Unstable handling Bent steering linkage
Joint in steering system worn or damaged
Incorrect steering pinion preload adjustment Fatigued coil spring
Faulty shock absorber(s) Lower arm bushing worn or damaged Incorrect toe-in adjustment (front or rear) Improper tire air pressure Wheel(s) bent or unbalanced
Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12
—
Excessive steering wheel play Faulty front wheel bearing Incorrect steering pinion preload adjustment Rack and pinion worn Joint in steering system worn or damaged Lower arm bushing worn or damaged
Adjust Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13
9-11
Tires excessively worn or worn un-evenly
Incorrect toe-in adjustment Improper tire air pressure Unbalanced wheel(s)
Refer to Section 13 Refer to Section 12 Refer to Section 12 —
Abnormal noise
from axle
Faulty wheel bearing Replace 9-11,18,23
86U09X-006
9—7

9 REAR AXLE
86U09X-027
69G09X-012
76G09X-003
REAR AXLE
ON-VEHICLE MAINTENANCE
Wheel Bearing Play
1.Jack up the vehicle and support it with safety
stands.
2. Check that there is no abnormal noise and that the
tire rotates smoothly when rotated by hand.
3. Remove the wheel.
4. Remove the caliper assembly and suspend it us-
ing a rope.
5. Position a dial indicator against the hub cap, then
push and pull the front wheel hub or brake drum
by hand in the axial direction and measure the end
play of the wheel bearing.
If the end play exceeds specification, replace the
wheel bearing.
End play: 0.2 mm (0.0079 in) max.
6. Install the caliper assembly. (Disc)
Tightening torque: 45—67 N-m
(4.6—6.8 m-kg, 33—49 ft-lb)
7. Install the wheel.
Tightening torque: 88—118 N-m
(9.0—12.0 m-kg, 65—87 ft-lb)
86U09X-029
9—16

REAR AXLE 9
[Drum Brake]
REMOVAL
Remove in the sequence shown in the figure referring to the removal note for the specially marked parts.
86U09X-030
1. Hub cap
2. Lock nut
3. Brake drum
4. Parking brake cable
5. Brake pipe
6. Back plate
7. Trailing link
8. Lateral link
9. Shock absorber
10. Knuckle spindle
11. Brake shoe assembly
Removal Note
Disconnect the brake pipe with the SST.
86U09X-03 I
9—17

9 REAR AXLE
DISASSEMBLY
Disassemble in the sequence shown in the figure referring to the disassembly note for the specially
marked parts.
1. Oil seal
2. Retaining ring
3. Rear wheel
bearing
4. Brake drum
86U09X-032
Disassembly Note
Bearing
Remove the rear wheel bearing with the SST.
86U09X-033
9—18

REAR AXLE 9
86U09X-034
61G09X-036
86U09X-035
INSPECTION
Knuckle Spindle
1. Cracks or damage.
2. Wear or rust on the oil seal contact surface.
Brake Drum
Wear or damage to brake drum.
Note Remove minor rust with sandpaper
ASSEMBLY
1. Install a new rear wheel bearing with the SST.
2. Install the retaining ring.
3. Install a new oil seal with the SST.
Note
Apply grease to the oil seal lip.
86U09X-036
9—19

9 REAR AXLE
INSTALLATION
Install in the reverse order of removal referring to the installation note.
Torque specifications
93—117 N m (9.5—11.9 m-kg, 69—86 ft-lb)
13—22 N-m (1.3—2.2 m-kg, 9—16 ft-lb)
86—117 N-m (8.8—11.9 m-kg, 64—86 ft-lb)
45—59 N-m (4.6-6.0 m-kg, 33—44 ft-lb)
98—177 N-m (10—18m-kg, 73—131 ft-lb)
86U09X-037
installation Note
Brake pipe
1. Connect the brake pipe with the SST.
Tightening torque: 13—22 N-m
(1.3—2.2 m-kg, 9—16 ft-lb)
2. Bleed the air. (Refer to Section 11)
End play
Measure the end play. (Refer to page 9—16)
86U09X-038
9—20

REAR AXLE 9
[Disc Brake]
REMOVAL (2WS)
Remove in the sequence shown in the figure.
1. Hub cap
2. Lock nut
3. Caliper assembly
4. Disc plate
5. Wheel speed sensor (ABS)
6. Dust cover
7. Trailing link
8. Lateral link
9. Shock absorber
10. Knuckle spindle
86U09X-039
9-21

REAR AXLE
REMOVAL (4WS)
Remove in the sequence shown in the figure referring to the removal note for the specially marked parts.
86U09X-040
1. Hub cap 7. Control link
2. Lock nut 8. Wheel speed sensor (ABS)
3. Parking brake cable 9. Stabilizer bracket
4. Caliper assembly 10. Tie-rod end
5. Disc plate 11. Shock absorber
6. Dust cover 12. Knuckle spindle
Removal Note
Tie-rod end
Remove the tie-rod end from the knuckle spindle with
the SST.
86U09X-041
9-22

11
BRAKING SYSTEM
OUTLINE 11—2
STRUCTURAL VIEW 11—2
SPECIFICATIONS 11— 4
TROUBLESHOOTING GUIDE 11— 5
ON-VEHICLE MAINTENANCE 11—6
BRAKE FLUID LEVEL IN MASTER
CYLINDER RESERVOIR 11— 6
BRAKE HYDRAULIC LINE 11—6
STRUCTURAL VIEW 11—6
ON-VEHICLE INSPECTION OF
BRAKE LINES 11— 8
REMOVAL AND INSTALLATION OF
BRAKE LINES 11— 9
REPLACEMENT OF BRAKE
FLUID 11— 9
AIR BLEEDING 11— 9
BRAKE PEDAL 11—11
ON-VEHICLE INSPECTION 11—11
REMOVAL 11—12
INSPECTION 11—13
INSTALLATION 11—13
MASTER CYLINDER 11—14
REMOVAL 11—15
DISASSEMBLY AND ASSEMBLY
(EXCEPT RHD DOHC TURBO).... 11—14
INSPECTION 11—17
DISASSEMBLY AND ASSEMBLY
(RHD DOHC TURBO) 11—18
INSPECTION 11—21
INSTALLATION 11—22
POWER BRAKE UNIT 11—27
FUNCTION CHECK 11—27
INSPECTION OF CHECK VALVE... 11—29
REMOVAL 11—29
DISASSEMBLY AND ASSEMBLY... 11—30
INSPECTION 11—32
INSTALLATION 11—33
VACUUM PUMP 11—35
ON-VEHICLE INSPECTION 11—35
REMOVAL AND INSTALLATION.... 11—35
DISASSEMBLY AND ASSEMBLY... 11—36
INSPECTION 11—37
DUAL PROPORTIONING VALVE 11—38
FUNCTION CHECK 11—38
REMOVAL AND INSTALLATION.... 11—39
FRONT DISC BRAKE 11—40
SIMPLE INSPECTION OF DISC
PAD WEAR 11—40
REPLACEMENT OF DISC PAD 11—40
REMOVAL 11—42
DISASSEMBLY AND ASSEMBLY... 11—43
INSPECTION 11—44
INSTALLATION 11—45
REAR DISC BRAKE 11—46
SIMPLE INSPECTION OF DISC
PAD WEAR 11—46
REPLACEMENT OF DISC PAD 11—46
REMOVAL 11—49
DISASSEMBLY AND ASSEMBLY... 11—50
INSPECTION 11—54
INSTALLATION 11—55
REAR DRUM BRAKE 11—56
REMOVAL 11—56
DISASSEMBLY AND ASSEMBLY
OF WHEEL CYLINDER 11—59
INSPECTION 11—60
INSTALLATION 11—61
PARKING BRAKE 11—65
ON-VEHICLE MAINTENANCE 11—65
REMOVAL AND INSTALLATION
OF PARKING BRAKE LEVER 11—66
REMOVAL OF PARKING BRAKE
CABLE 11—68
INSTALLATION OF PARKING
BRAKE CABLE 11—69
ANTI-LOCK BRAKE SYSTEM
(ABS) 11—71
STRUCTURAL VIEW 11—71
WIRING DIAGRAM 11—72
TROUBLESHOOTING 11—73
DIAGNOSIS INDICATION MODE ... 11—86
MEMORY CANCEL 11—86
ABS WARNING LIGHT 11—87
RELAY BOX 11—87
WHEEL SPEED SENSOR 11—87
SENSOR ROTOR 11—90
HYDRAULIC UNIT FLUID 11—94
HYDRAULIC UNIT 11—94
CONTROL UNIT CIRCUIT 11—99
76G11X-001

1 1 OUTLINE
OUTLINE
STRUCTURAL VIEW
i
Front disc/rear drum brake
4-wheel disc brake
1. Brake pedal
2. Power brake unit
3. Brake master cylinder
4. Parking brake lever
5. Dual proportioning valve
6. Front disc brake
86U11X-002
7. Rear drum brake
8. Parking brake cable
9. Rear disc brake
11—2