MAZDA MX-5 1994 Workshop Manual

P BRAKE SYSTEM Installation note Disc pad 1. Push the piston inward by using the 2. Install the new pads in the mounting SST. support. 1 I 15UOPX-030 Removal I lnstallation (Caliper) 1. On level ground, jack up the front of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure. 3. Install in the reverse order of removal. 4. Tighten all nuts and bolts to the specified torques, referring to the figure. 1. Brake hose 5. Shim 2. Connecting bolt 6. Bolt 3. Caliper 7. Mounting support Disassembly / Inspection / 8. Disc plate Assembly .................. page P-28 Inspection ................... page P-27 4. Disc pad ................... Inspection page P-27 Gartner Banana

BRAKE SYSTEM P Inspection Check the following and repair or replace parts as neces- sary. Disc pad 1. Oil or grease on facing. 2. Abnormal wear or cracks. 3. Deterioration or damage by heat. 4. Remaining lining thickness. Thickness Standard: 8.0mm (0.31 in) Minimum: 1 .Omm (0.04 in) Disc plate Tighten the disc plate to the wheel hub by using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface. 1. Runout. Runout: O.lmm (0.004 in) max. 2. Wear and damage. Thickness Standard: 20.0mm (0.79 in) Minimum: 18.0mm (0.71 in) Gartner Banana

P BRAKE SYSTEM CALIPER Disassembly I Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal. REPLACE 1. Dust seal 3. Piston seal Inspect for damage and poor sealing Disassembly Note ................ below 2. Piston 4. Bleeder screw and bleeder cap Disassembly Note ................ below 5. Caliper body Inspect for wear and rust Inspect for damage and cracks Disassembly note Piston 1. Place a piece of wood in the caliper. 2. Gently blow compressed air through the hole to force the piston out of the caliper. 9MUOPX-075 Piston seal Remove the piston seal by using the SST. Gartner Banana

BRAKE SYSTEM ,$, .... "P ...% REAR BRAKE (DISC) Quick Inspection, On-vehicle Disc pad 1. On level ground, jack up the rear of the vehicle and sup- port it with safety stands. 2. Remove the wheels. 3. Sight through the caliper inspection hole and verify the remaining thickness of the pad. Thickness: 1 .Omm (0.04 in} min. I I 05UOPX-043 Replacement (Disc pad) 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to Installation Note. 1. Plug 4. M-spring 2. Manual adjustment gear 5. Disc pad Removal Note ................... below Inspection ................... page P-31 Installation Note ............. page P-30 6. Shim 3. Lock bolt 7. Guide plate RETRACTING BRAKE PADS Removal note Manual adjustment gear Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston back. Gartner Banana

BRAKE SYSTEM ADJUSTING BRAKE PADS Installation note Manual adjustment gear 1. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate. -1 2. Return the manual adjustment gear counterclockwise 113 turn. Removal 1 lnstallation (Caliper) 1. On level ground, jack up the rear of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Inspect all parts and repair or replace as necessary. 5. Tighten all nuts and bolts to the specified torques, referring to the figure. Parking brake cable Removal I Inspection 1 Installation ................. page P-36 Connecting bolt Brake hose Plug Manual adjustment gear Removal Note ............... page P-29 Installation Note ................. above Lock bolt 7. Caliper Disassembly I Inspection 1 Assembly .................. page P-32 8. Disc pad Replacement ................ page P-29 Inspection ................... page P-31 9. Bolt 10. Mounting support 11. Disc plate Inspection ................... page P-31 Gartner Banana

BRAKE SYSTEM P Inspection Check the following and repair or replace parts as neces- sary. Disc pad 1. Oil or grease on facing. 2. Abnormal wear or cracks. 3. Deterioration or damage by heat. 4. Remaining lining thickness. Specified thickness : 8.0mm (0.31 in) Minimum : l.Omm (0.04 in) Disc plate Tighten the disc plate to the wheel hub by using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface. 1. Runout. Runout: O.lmm (0.004 in) max. 2. Wear or damage. Thickness Standard: 9.0mm (0.35 in) Minimum: 8.0mm (0.31 in) Gartner Banana

P BRAKE SYSTEM CALIPER Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. REPLACE Up /REPLACE REPLACE kf'h \u b REPLACE 1. Dust seal lnspect for damage and poor sealing 2. Piston Disassembly Note ................ below Assembly Note .............. page P-33 lnspect for wear and rust 3. Manual adjustment gear 4. Snap ring 5. Adjusting bolt 6. O-ring 7. Connecting link 8. Piston seal Disassembly Note ............ page P-33 9. Spring 10. Operating lever 11. Boot 12. Cap and bleeder screw 13. Boot 14. Boot 15. Caliper body lnspect for damage and cracks Disassembly note Piston 1. Turn the manual adjustment gear clockwise with an Allen wrench. (Turn the manual adjustment gear until it turns easily.) 2. Remove the piston. Gartner Banana

BRAKE SYSTEM P Piston seal Remove the piston seal by using the SST. Assembly note Piston Insert the piston into the caliper and turn the adjustment gear counterclockwise with an Allen wrench to pull the piston in fully. (Turn the adjustment gear until it stops.) Gartner Banana

P PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM TROUBLESHOOTING GUIDE I Problem I Possible cause I Brake fluid or oil on pads -- Brakes do not release Parking brake does not hold well I Hardening of pad surfaces or poor contact Improper return of parking brake cable or improper adjustment Excessive lever stroke Brake cable stuck or damaged Action 1 page 1 d Repair or adjust Adjust Repair or replace Clean or replace Grind or replace 25UOPX-026 PARKING BRAKE LEVER Inspection 1. Depress the brake pedal several times. 2. Verify that the stroke is within specification when the parking brake lever is pulled with a force of 196 N (20 kgf, 44 Ibf). Stroke: 7-9 notches Adjustment 1. On level ground, jack up the rear of the vehicle until the wheels are free to turn, and support it with stands. 2. Depress the brake pedal several times. 3. Remove the cover. 4. Turn the adjusting nut to adjust the lever stroke. --/, 5. Depress the parking brake pedal one notch, and verify that the parking brake warning light comes on. Release the parking brake. 6. Turn the wheels by hand, and verify that the brakes do not drag. 7. Lower the vehicle. Gartner Banana

PARKING BRAKE SYSTEM P Removal 1 Inspection / lnstallation 1. Block the wheels firmly. 2. Release the parking brake. - 3. Remove in the order shown in the figure. 4. lnspect all parts and repair or replace as necessary. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. After installation, adiust the arki in^ lever stroke. (Refer to page P-34.) 1. Screw 6. Release button 2. Cover 7. Spring 3. Bolt Inspect for weakness 4. Parking brake switch 8. Bolt lnstallation Note . . . . . . . . . . . . . . . . . below 9. Parking brake lever lnspect for damage and cracks 5. Adjusting nut and clip lnstallation note Parking brake switch 1. Install the parking brake switch so that it contacts the parking brake lever when the lever is fully released. 2. Turn the ignition switch ON, and verify that the parking brake warning light illuminates with the lever pulled up one notch. Gartner Banana