lock MAZDA MIATA 1991 Factory Workshop Manual

ApplicationFt. Lbs. (N.m)
Axle Shaft Lock Nut (1) 159-217 (216-294)
Differential-To-Axle Shaft Flange Nuts (4)40-47 (54-64)
Upper Control Arm Bolt/Nut34-49 (46-66)
Wheel Lug Nuts65-87 (88-118)
(1)Non-reuseable part. Manufacturer recommends replacing axle shaft lock nut on installation.

1991 Mazda MX-5 Miata
1990-93 DRIVE AXLES Axle Shafts - MX-5 Miata
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BRAKE SYSTEM
1991 BRAKES Mazda Brake System
DESCRIPTION & OPERATION
All models use hydraulic-operated brake system with a tandem master cylinder and a power brake unit.
BRAKE SYSTEM BLEEDING
BRAKE LINE BLEEDING SEQUENCE
ADJUSTMENTS
MASTER CYLINDER PUSH ROD (NAVAJO)
1. Remove master cylinder to gain access to push rod. To check screw adjustment, fabricate a gauge. See
Fig. 1
. NOTE: For information on anti-lock brake systems, see appropriate ANTI-LOCK BRAKE
SYSTEM article in the BRAKES Section.
NOTE: See BRAKE BLEEDING article in the BRAKES Section.
ApplicationSequence
Protege & 323RR, LR, LF, RF
RX7 (1) RR, LR, RF, LF
All OthersLongest Line First
(1)If rear caliper has not been disassembled, open upper bleed valve only.
NOTE: Push rod has an adjustment screw to maintain correct distance between
booster push rod and master cylinder piston. If push rod is adjusted too long, it
prevents master cylinder piston from completely releasing hydraulic pressure,
causing brakes to drag. If push rod is adjusted too short, it causes excessive
pedal travel and an undesirable clunk in booster area.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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1. Raise and support rear of vehicle. Ensure parking brake is released. Remove plugs from rear of backing
plate (one below wheel cylinder, other near outer diameter of backing plate). Insert a screwdriver through
hole below wheel cylinder. Rotate star wheel adjuster in direction of arrow stamped on backing plate until
wheel locks.
2. Insert a drift through other hole in backing plate. Push pawl back from adjuster and back off adjuster 6-7
notches. Ensure wheel rotates freely. Perform same procedure on both sides. Adjust parking brake.
B2600i 4WD & MPV
1. Raise and support rear of vehicle. Ensure parking brake is released. Remove plugs from rear of backing
plate. Insert a screwdriver through hole for star wheel. Rotate adjuster in direction of arrow stamped on
backing plate until wheel locks.
2. Insert a drift through other hole in backing plate. Push pawl back from adjuster and back off adjuster 8-10
notches (13-15 notches on MPV). Ensure wheel rotates freely. Perform same procedure on both sides.
Adjust parking brake.
MX-6, Protege, 323 & 626
1. Raise and support rear of vehicle. Remove wheel. Release parking brake. Remove lock nut from axle
shaft. Remove brake drum. Insert screwdriver between adjusting plate and quadrant. Twist screwdriver to
disen
gage teeth. See Fig. 2 or Fig. 3 .

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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Fig. 3: Moving Quadrant on Rear Brake Adj. (Typical Protege & 323)
Courtesy of MAZDA MOTORS CORP.
2. Push adjusting lever toward backing plate. Install brake drum. Install new lock nut, and secure by
crimping. Operate parking brake a few times to reset adjuster. Adjust parking brake.
Navajo
1. Raise and support rear of vehicle. If drums are installed on vehicle, remove cover from adjusting hole at
bottom of brake backing plate. Turn adjusting screw with a brake adjusting tool until shoes drag against
brake drum and lock drum.
2. When shoes are against drum, loosen adjusting screw an additional 10-12 notches so drum rotates freely.
If drum does not rotate freely, remove wheel and drum and vacuum dust and dirt from linings. Use
sandpaper and remove rust from points where shoes touch backing plate. Apply a light coating of
molybdenum grease to brake shoe-to-backing plate contact points. Install wheel and drum and adjust
shoes.
3. To adjust brakes with rear drums removed, first clean all rust and dirt on points where shoes touch
backing plate and apply a small amount of molybdenum grease to those areas. Use a brake shoe
adjustment gauge and adjust brakes to inside diameter of drum braking surface.
4. Reverse tool and adjust brake shoes until they touch gauge. Gauge contact points on shoes must be
parallel to vehicle with center line throu
gh center of axle. Hold automatic adjusting lever out of

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates
freely.
PARKING BRAKE
B2200 & B2600i
1. Depress brake pedal several times while vehicle is moving in Reverse. Ensure brakes are properly
adjusted. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-12 notches, parking brake
is properly adjusted.
2. If stroke is not 7-12 notches, raise and support rear of vehicle. Release parking brake lever. Loosen cable
lock nut at lever end of cable. Rotate adjusting nut until correct stroke is obtained. Operate parking brake
several times and ensure rear wheels rotate freely. Ensure parking brake warning light illuminates when
brake lever is pulled one notch.
Navajo
1. Adjust service brakes before adjusting parking brake cable. Ensure brake drums are cold. Apply parking
brake to fully depressed position. Grip threaded rod to prevent it from spinning.
2. Thread equalizer nut 6 full turns past its original position on threaded rod. See Fig. 4
. Check cable
tension at rear of equalizer assembly using Cable Tension Gauge (021-00018). If tension is not 400-600
lbs. (182-272 k
g), repeat step 2).

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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2. Release parking brake lever. Using a screwdriver, reach through parking brake handle hole in console and
rotate adjusting screw until stroke is 6-8 notches. Ensure rear wheels rotate freely. Ensure parking brake
warning light illuminates when brake lever is pulled one notch.
Miata, MX-6, MPV, Protege, RX7, 323, 626
1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes,
start engine and depress brake pedal several times while vehicle is moving in Reverse. Stop engine.
2. On all models, pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 5-7 notches, parking
brake is properly adjusted. If stroke is not 5-7 notches, raise and support rear of vehicle. Release parking
brake lever.
3. Rotate cable adjusting nut at lever end of cable (under console cover) until stroke is within specification.
On models equipped with rear disc brakes, ensure clearance between stopper and lever (at each caliper) is
not less than .08" (2 mm) on RX7, or zero on all other models. On all models, ensure parking brake
warning light illuminates when brake lever is pulled one notch.
PARKING BRAKE SHOES
929
Raise and support vehicle. Remove rear wheels. Remove service plug from rotor. Using a screwdriver, rotate
star wheel adjuster toward axle until rotor locks. Rotate adjuster in opposite direction 3-5 notches. Ensure rotors
turn freely and parking brake functions properly. Install service plug and rear wheels.
PEDAL FREE PLAY
Depress pedal a few times to eliminate vacuum. Pedal free play should be .16-.28" (4-7 mm). Adjust play by
loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut.
PEDAL HEIGHT & STOPLIGHT SWITCH
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Move switch away
from pedal. Loosen push rod lock nut. Turn rod until correct pedal height is obtained. See BRAKE
PEDAL HEIGHT SPECIFICATIONS .
2. Adjust pedal free play. See PEDAL FREE PLAY
under ADJUSTMENTS. Tighten push rod lock nut.
Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut. Reconnect stoplight switch electrical connector.
3. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. On B2200, B2600i and MPV, depress brake pedal with 33 lbs. (15 kg) pressure. On all other
models, depress brake pedal with 132 lbs. (60 k
g) pressure. tension should be checked and adjusted.
NOTE: Pedal height and stoplight switch information is not available for Navajo.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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Fig. 6: Front Disc Brake Assembly (RX7 with 4-Piston Caliper)
Removal & Installation (All With Single-Piston Caliper)
Raise and support front of vehicle. Remove wheels. Remove lower lock pin/guide bolt. See Fig. 7 , Fig. 8 , Fig.
10 , Fig. 11 , or Fig. 12 . Pivot caliper upward, and support using rope. Remove brake pads. Replace pad if
lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE.
To install, reverse removal procedure.
MINIMUM PAD LINING SPECIFICATIONS (FRONT)
ApplicationThickness In. (mm)
B2200, B2600i & Navajo.12 (3.0)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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Removal & Installation (B2200 & B2600i 2WD)
1. With caliper assembly removed, remove wheel hub grease cap, cotter pin, lock plate and ring adjusting
lock nut. Remove thrust washer and outer bearing from hub. Slide hub and rotor assembly from spindle.
2. Mark rotor-to-hub position. Separate rotor from hub. Machine rotor if lateral runout exceeds
specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC
BRAKE SPECIFICATIONS at end of article.
3. To install, reverse removal procedure and evenly tighten rotor-to-hub bolts. Adjust wheel bearings.
Removal & Installation (B2600i 4WD) 1) Remove front caliper. Set hub to FREE position. Remove hub
bolts. Remove hub as an assembly. Install 2 bolts and nuts to retain hub assembly together. Remove snap
ring and spacer.
4. Remove set bolt and plate. Remove nut. Remove rotor and hub assembly. Mark rotor-to-hub position.
Remove rotor from hub. Machine rotor if lateral runout exceeds specification. Replace rotor if measured
thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS
at end of
article. To install, reverse removal procedure.
Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 323 & 626)
1. Raise and support front of vehicle. Remove wheel. Remove caliper with brake hose connected. Support
caliper using rope. Remove 2 rotor-to-hub screws. Remove rotor.
2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than
specified minimum thickness. See DISC BRAKE SPECIFICATIONS
at end of article. To install,
reverse removal procedure.
Removal & Installation (Navajo 2WD)
1. Raise vehicle, and support using safety stands. Remove wheel and caliper assemblies. Remove dust cap,
cotter pin, nut, washer and outer bearing. Carefully remove hub and rotor assembly. Remove inner
bearing and seal.
2. To install, reverse removal procedure. Adjust front wheel bearings. While rotating rotor, tighten adjusting
nut to 17-25 ft. lbs. (23-34 N.m). Back off adjusting nut 120-180 degrees. Install bearing retainer and new
cotter pin.
Removal (Navajo 4WD With Automatic Locking Hubs)
1. Raise vehicle, and support using safety stands. Remove wheel assembly and caliper. See FRONT DISC
BRAKE PADS under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs.
Remove automatic locking hub housing from spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacer. See Fig. 13
. Carefully pull plastic
moving cam off wheel bearing adjusting nut. Remove 2 plastic thrust spacers from adjusting nut. Using a
magnet, remove locking key.
CAUTION: DO NOT pry on plastic cam or spacers during removal as damage
may result. To prevent damaging spindle threads, remove locking
key before removing adjusting nut.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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Fig. 13: Removing Front Rotor (Navajo with Automatic Locking Hubs)
Courtesy of FORD MOTOR CO.
3. If necessar
y, rotate adjusting nut slightly to relieve pressure on locking key. Using Hex Lock Nut Wrench

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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(T70T-4252-B), remove wheel bearing adjusting nut. Remove outer wheel bearing, and then remove
rotor.
Installation
When installing rotor, outer bearing and adjusting nut, tighten adjusting nut to 35 ft. lbs (47 N.m) to seat
bearings. Spin rotor, and back off adjusting nut 1/4 turn. Tighten adjusting nut to 16 INCH lbs. (1.8 N.m). To
install remaining components, reverse removal procedure. See Fig. 13
. After assembly is complete, wheel to
spindle end play should be .001-.003" (.02-.08 mm).
Removal (Navajo 4WD With Manual Locking Hubs)
1. Raise and support vehicle. Remove wheel assembly and caliper. See FRONT DISC BRAKE PADS
under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs. Remove manual
locking hub housing from spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacer. See Fig. 14
. Using Lock Nut Wrench
(T86T-1197-A), remove outer wheel bearing lock-nut. Remove lock washer. Using Lock Nut Wrench
(T86T-1197-A), remove inner wheel bearing lock nut, outer wheel bearing and rotor. CAUTION: Extreme caution must be used when aligning adjusting nut lug with
spindle locking key slot to prevent damage to locking key. Extreme
caution must be used when aligning fixed cam key with spindle key slot to
prevent damage to fixed cam.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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