brake pads MAZDA MX-5 1994 Workshop Manual

BRAKE SYSTEM P BRAKE SYSTEM PREPARATION - SST Wrench, flare nut 49 0221 600C Expand tool, disc brake 49 8043 001 Adjust gauge 49 8043 004 Wrench, socket Gauge, oil pressure (Part of 49 U043 OAO) - 49 U043 006 Hose (Part of 49 U043 OAO) For removal and installation brake PIPS For installation of disc pads 49 F043 001 Adjust gauge For Adjustment of push rod clearance For adjustment of push rod clearance 49 0208 701 A Boot air out tool For adjustment of push rod clearance For inspection of brake fluid pressure For removal of piston seal 49 8043 003 Lock tool, turning For inspection of brake fluid pressure For adjustment of push rod clearance 49 U043 OAO Gauge set, oil pressure & - For inspection of brake fluid pressure 49 U043 005 Joint (Part of ,-, 49 U043 OAO) For inspection of brake fluid pressure Gartner Banana

BRAKE SYSTEM TROUBLESHOOTING GUIDE Problem Poor braking Brakes pull to one side Brakes do not release Pedal goes too far (Too much pedal stroke) Abnormal noise or vibra- tion durlng braking Possible cause Leakage of brake fluid Air in lines Worn pad Brake fluid, grease, oil, or water on pad Hardening of pad surface or poor contact Malfunction of disc brake piston Malfunction of master cylinder Malfunction of power brake unit Malfunction of check valve (vacuum hose) Damaged vacuum hose Deterioration of flexible hose Malfunction of proportioning bypass valve (PBV) Worn pad Brake fluid, grease, oil, or water on pad Hardening of pad surface or poor contact Abnormal wear, distortion, or eccentricity of disc Malfunction of automatic adjuster in rear brake Looseness or deformation of dust cover mounting bolt Malfunction of disc brake piston Worn or improperly adjusted wheel bearing preload lmproper adjustment of wheel alignment Unequal tire air pressure No brake pedal play lmproper adjustment of push rod clearance Clogged master cylinder return port Pad not returning properly lmproper return of malfunction of brake caliper piston Excessive runout of disc plate lmproper adjustment of wheel bearing preload Air in system because of insufficient brake fluid lmproper adjustment of pedal play Worn pad Air in lines Worn pad Deterioration of pads Brakes do not release Foreign material or scratches on disc plate contact surface Looseness of caliper mounting bolt(s) Damage or deviation of disc contact surface Poor contact of pads Insufficient grease on sliding parts Action Repair Air bleed Replace Clean or replace Grind or replace Replace Repair or replace Repair or replace Repair or replace Replace Replace Replace Replace Clean or replace Grind or replace Repair or replace Repair Tighten or replace Repair or replace Replace or adjust Adjust Adjust Adjust Adjust Clean Repair Replace Replace Adjust or replace Add fluid and bleed air Adjust Replace Bleed air Replace Grind or replace Repair Clean Tighten Replace Repair or replace Apply grease Page - P- 7 P-25,29 P-25,29 P-25,29 P-28,32 P-11, 14 P-22 P-22 P-22 P- 7 P-23,24 P-25,29 P-25,29 P-25,29 section M - section M P-28,32 section M section R section Q P- 9 P-l2,15 - - P-28,32 section M section M P- 7 P- 9 P-25,29 P- 7 P-25,29 P-25,29 - - P-26,30 section M P-25,29 - 15UOPX-00 Gartner Banana

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 ...% 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

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