MAZDA MX-5 1997 Factory Repair Manual

as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
BRAKE PEDAL HEIGHT SPECIFICATIONS
Millenia & Protege
1. Released pedal height is measured between brake pedal and stoplight switch mounting bracket. See Fig.
3 . Disconnect stoplight switch electrical connector and remove switch. Measure length "L" between
stoplight switch mounting bracket and brake pedal. See Fig. 3
. On Millenia, length should be .79-
.90" (20-23 mm). On Protege, length should be .71-.86" (18-22 mm).
2. On all models, if clearance is as specified, install stoplight switch. No adjustment is necessary. If
clearance is not as specified, loosen lock nut "B" and rotate self-locking nut "A" counterclockwise until it
does not contact brake pedal.
3. Loosen push rod lock nut and rotate push rod until correct clearance between brake pedal and stoplight
switch mounting bracket is obtained. Tighten push rod lock nut. Rotate self-locking nut "A" clockwise
until clearance between brake pedal and end of self-locking nut "A" is .004-.039 (.1-1.0 mm). See Fig. 3
.
Tighten lock nut "B".
4. Install NEW stoplight switch. Stoplight switch is automatically adjusted by pulling back on brake pedal
until stoplight switch click noise is heard. Reconnect stoplight switch electrical connector. Check
stoplight operation. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock
nut to 18-25 ft. lbs. (24-34 N.m).
5. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure. On Millenia, distance should be 2.7" (70
mm). On Protege, distance should be 3.8" (95 mm). On all models, if distance is not as specified, check
ApplicationIn. (mm)
Pedal Released
Miata6.8-7.1 (171-181)
MPV7.5-7.9 (191-201)
MX-37.6-7.7 (193-196)
MX-6 & 6267.5-7.7 (191-196)
RX76.5-6.9 (165-176)
9297.4-7.7 (188-195)
Pedal Applied (1)
Miata3.7 (95)
MPV, MX-6 & 6263.3 (85)
MX-32.8 (70)
RX73.9 (100)
9291.6 (40)
(1)Minimum height.
NOTE: When adjusting brake pedal height, a NEW stoplight switch must be used.
Stoplight switch can only be adjusted one time.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
Fig. 3: Adjusting Brake Pedal Height (Millenia Shown; Protege Is Similar)

Courtesy of MAZDA MOTORS CORP.
TESTING
PROPORTIONING VALVE
NOTE: B2300, B3000 and B4000 are not equipped with a proportioning valve.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
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1. Connect 2 pressure gauges and adapters to proportioning valve. One to input port and other to output port.
Bleed brake system. See BLEEDING BRAKE SYSTEM
. Depress brake pedal until pressure gauge
reads as specified and check output pressure. See PROPORTIONING VALVE PRESSURE
SPECIFICATIONS .
2. Depress brake pedal again, applying additional pressure. Recheck output pressure. See
PROPORTIONING VALVE PRESSURE SPECIFICATIONS
. If output pressure is not as specified,
replace proportioning valve.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS
ApplicationInlet Pressure psi (kg/cm2 )
Outlet Pressure psi
(kg/cm
2 )
Miata
With ABS569 (40) 850 (60)526-612 (37-43) 626-740
(44-52)
Without ABS427 (30) 850 (60)384-470 (27-33) 540-654
(38-46)
Millenia430 (31) 850 (60)400-460 (28-32) 520-600
(37-42)
MPV
1995512 (36) 1422 (100)484-540 (34-38) 854-995
(60-70)
1996-97427 (30) 853 (61)370-484 (26-34) 583-697
(41-49)
MX-3
With ABS356 (25) 853 (61)328-384 (23-27) 512-598
(36-42)
Without ABS427 (30) 853 (61)399-455 (28-32) 512-598
(36-42)
MX-6 & 626
With ABS500 (35) 850 (60)470-530 (33-37) 597-683
(42-48)
Without ABS500 (35) 850 (60)470-530 (33-37) 557-643
(39-45)
Protege
With ABS356 (25) 853 (61)328-384 (23-27) 568-654
(40-46)
Without ABS 1.5L356 (25) 853 (61)328-384 (23-27) 483-569
(34-40)
Without ABS 1.8L356 (25) 853 (61)328-384 (23-27) 654-740
(46-52)
RX7570 (40) 850 (60)530-610 (37-43) 626-739
(44-52)
929427 (30) 853 (61)399-455 (28-32) 541-654

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.

POWER BRAKE UNIT
1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake
pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal
does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is
operating. If length of strokes is equal, check valve and vacuum hose between vacuum source and power
brake unit. Repair as necessary, and go to next step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake unit is operating. If pedal height recedes, check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (B2300, B3000 & B4000)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder reservoir. Raise and support vehicle. Remove front wheel assemblies. Place a
large "C" clamp on caliper.
2. Tighten clamp to bottom piston in cylinder bore. Remove clamp. Remove 2 caliper pin bolts. Remove
caliper from rotor and wire aside. Slide brake pads off caliper anchor plate. Remove anchor plate (if
necessary). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING
SPECIFICATIONS (FRONT) .
3. To install, reverse removal procedure. Use "C" clamp and old pad to push caliper piston into piston bore
until piston bottoms out. Bleed air from brake system (if necessary).
Removal & Installation (Miata, Millenia, MPV, MX-6, 626 & 929)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt.
See Fig. 4
, Fig. 5 or Fig. 6 . Pivot caliper upward and support using rope.
2. Remove pads, shims, guide plates or pad guides and "V" springs (if equipped). Replace pad if lining
thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT)
.
3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push
piston full
y inward to install disc pads.
(38-46)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 10 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Exploded View Of Front Disc Brake Assembly (Miata Shown; MPV Is Similar)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Exploded View Of Front Brake Disc Assembly (MX-6 & 626)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Fig. 6: Exploded View Of Front Disc Brake Assembly (929 Shown; Millenia Is Similar)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-3 & Protege)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove "M" spring. See Fig. 7 .
Remove "W" spring. Remove pad pins. Remove pads, shims and anti-squeak shim. Replace pad if lining
thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT)
.
2. To install, reverse removal procedure. Use Disc Brake Expand Tool (49-0221-600C) and an old pad to
push piston full
y inward to install disc pads.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Fig. 7: Exploded View Of Front Disc Brake Assembly (MX-3 & Protege)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (RX7)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove "M" clip. See Fig. 8 .
Remove pad pins. Remove "M" spring. Remove pads and shims. Replace pad if lining thickness is less
than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT)
.
2. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push
piston fully inward to install disc pads. Ensure shims are installed with arrows facing direction of forward
rotor rotation.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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MINIMUM PAD LINING SPECIFICATIONS (FRONT)
Fig. 8: Exploded View Of Front Disc Brake Assembly (RX7)

Courtesy of MAZDA MOTORS CORP.
FRONT DISC BRAKE CALIPER
Removal & Installation (Except B2300, B3000 & B4000)
Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all
ApplicationThickness In. (mm)
B2300, B3000 & B4000.12 (3.0)
Miata, MX-6, Protege, RX7, 626 & 929.04 (1.0)
Millenia, MPV & MX-3.08 (2.0)
NOTE: For removal and installation of front disc brake caliper for B2300, B3000 &
B4000, see FRONT DISC BRAKE PADS
.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.

openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS. Remove remaining mounting
bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system.
FRONT BRAKE ROTOR
Removal & Installation (B2300, B3000 & B4000 2WD)
1. Raise and support vehicle. Remove front wheel assemblies and brake caliper. See FRONT DISC
BRAKE PADS . Remove grease cap, cotter pin, retainer, adjusting 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 17-25 ft. lbs. (23-34 N.m) to seat bearings. Back off adjusting nut 1/2 turn. Tighten adjusting nut to
18-20 INCH lbs. (2.0-2.3 N.m). Install bearing retainer and NEW cotter pin. DO NOT turn adjusting nut
to align cotter pin.
Removal (B2300, B3000 & B4000 4WD With Automatic Locking Hubs)
1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE
PADS . Remove retainer washers from lug nut studs. Remove automatic locking hub assembly from
spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 9
. Carefully pull cam
assembly off wheel bearing adjusting nut. If necessary, rotate adjusting nut slightly to relieve pressure on
locking key.
3. Using a magnet, remove locking key. Using 2 3/8" Hex Lock Nut Wrench (49-UN01-037), remove wheel
bearing adjusting nut. Remove outer wheel bearing and 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. 7
. After assembly is complete, wheel to
spindle end play should be .000-.003" (.00-.08 mm).
CAUTION: Extreme caution must be used when aligning adjusting nut lug with
spindle locking key slot to prevent damage to locking key.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.