boot MAZDA 626 1987 Repair Manual

1 1 POWER BRAKE UNIT
Removal Note
Steering Shaft
To remove the mounting nuts of the power brake unit,
the steering shaft must be removed. (Refer to page
10—22 for removal and installation procedures.)
76G11X-102
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to disassembly note for specially marked
parts.
2. Inspect each part, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
8.8—13 N-m (90-130 cm-kg, 78—112 in-lb)
1. Dust boot
2. Rear shell assembly
3. Retainer
4. Bearing
5. Dust seal
6. Retainer
7. Air filters
8. Air silencer
9. Diaphragm and plate
10. Power piston assembly
11. Retainer key
12. Valve rod and plunger as-
sembly
13. Reaction disc
76G11X-070
14. Spring
15. Push rod
16. Front shell assembly
17. Retainer
18. Seal
19. Vacuum switch (RF, RF-CX)
11-30

FRONT DISC BRAKE 1 1
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to disassembly note for specially 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-079
1. Snap ring
2. Dust seal
3. Piston
4. Piston seal
5. Guide pin
6. Pin boot
7. Bushing
8. Cap
9. Bleeder screw
Disassembly Note
Piston
Place a piece of wood in the caliper; then blow com-
pressed air through the hose connection hole to force
out the piston.
Caution
Blow the compressed air a little at a time to
prevent the piston from popping out.
76G11X-080
Piston seal
Remove the piston seal from the caliper with the SST.
86U11X-074
11-43

1 1 FRONT DISC BRAKE
86U11X-075
76G11X-081
86U11X-077
Inspection Note
Check the following and replace any faulty parts.
1. Cylinder and piston for wear or rust
2. Caliper body for damage or cracks
3. Boot for damage or poor sealing
Assembly Note
Application of grease
Coat the following parts with the grease supplied in
the seal kit.
1. Piston seal
2. Dust seal
3. Guide pin
4. Guide pin boot
5. Bushing
Piston
Coat the piston and the cylinder with brake fluid; then
insert the piston straight into the cylinder.
86U11X-078
11—44

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
11-50

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
11-56

REAR DRUM BRAKE 1 1
DISASSEMBLY AND ASSEMBLY OF WHEEL CYLINDER
1. Disassemble in the sequence shown in the figure.
2. Inspect all parts, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for the specially marked
parts.
Caution
Do not damage the piston or cylinder. Do not let foreign material into the cylinder.
Note Use new piston cups when installing.
76G11X-087
1. Dust boot
2. Piston
3. Piston cup
4. Spring
5. Rubber cap
6. Bleeder screw
7. Steel ball
8. Wheel cylinder body
V ^
Inspection Note
Check the following and repair or replace any faulty
parts.
1. Weak or broken spring
2. Worn, rusted, or damaged wheel cylinder
86U11X-115
11—59

FRONT SHOCK ABSORBER AND SPRING 1 3
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to the disassembly note for specially
marked parts.
2. Inspect all components and parts, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to the assembly note for specially marked
parts.
4. Tighten all nuts and bolts to the specified torque, referring to the figure.
76G13X-014
1. Nut
2. Actuator bracket
3. Mounting block
4. Bearing
5. Spring upper seat
6. Spring seat
7. Dust boot
8. Bound stopper
9. Coil spring
10. Shock absorber
13—15

FRONT SHOCK ABSORBER AND SPRING 1 3
Assembly Note
1. Set the SST in a vise
2. Secure the shock absorber in the SST.
3. Install the bound stopper and dust boot to the
shock absorber.
4. Install the compressed coil spring (compressed
with SST).
5. Install the rubber seat, spring upper seat, bearing
and mounting block.
86U13X-021
6. Remove the SST.
7. Secure the mounting block in a vise.
Caution
Use copper or aluminum plates in the jaws of
a vice.
8. Tighten the piston rod upper nut.
Tightening torque:
64—84 Nm (6.5—8.2 m-kg, 47—59 ft-lb)
Caution
Check that the spring is well seated in the up-
per seats.
13—17

1 3 FRONT LOWER ARM
Inspection Note
Check the following and repair or replace any faulty
parts.
1. Lower arm for damage or cracks
2. Preload of ball joint
3. Bushings for deterioration or wear
4. Dust boot for damage
Note
If it is necessary to replace the ball joint, re-
place the lower arm assembly.
86U13X-027
Ball joint preload
Attach the SST to the ball stud, and measure the
preload with a pull scale.
Caution
Measure the preload after shaking ball joint
the stud 3 or 4 times.
86U13X-028
Lower arm bushing (Front)
Removal
1. Cut away the projecting rubber of the lower arm
bushing.
2. Set the SST on the lower arm and remove the
bushing.
86U13X-029
Installation
Apply soapy water to the new bushing, then pull it
into the lower arm with the SST.
86U13X-030
13—20

FRONT LOWER ARM 1 3
86U13X-031
86U13X-032
86U13X-033
Lower arm bushing (Rear)
Removal
Set the SST on the lower arm and remove the
bushing.
Installation
Install the new bushing, and then pull it into the low-
er arm with the SST.
Ball joint dust boot
Removal
Remove the dust boot with a chisel.
Caution Do not damage the ball joint.
Installation
1. Liberally coat the inside of the new dust boot with
grease.
2. Install the dust boot onto the ball joint with the SST.
86U13X-034
13—21