MAZDA MX-5 1997 Factory Repair Manual

Fig. 9: Removing Front Rotor (B2300, B3000 & B4000 With Automatic Locking Hubs)
Courtesy of FORD MOTOR CO.
Removal (B2300, B3000 & B4000 4WD With Manual 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 manual locking hub assembly from
spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 10
. Using Lock Nut Wrench
(49-UN01-042), remove outer wheel bearing lock nut. Remove lock washer. Using lock nut wrench,
remove inner wheel bearing lock nut. Remove outer wheel bearing, cup and rotor.
Installation
When installing rotor, outer bearing and inner lock nut, tighten inner lock nut to 35 ft. lbs. (47 N.m) to seat
bearings. Spin rotor, and back off inner lock nut 1/4 turn. Tighten inner lock nut to 16 INCH lbs. (1.8 N.m). To
install remaining components, reverse removal procedure. See Fig. 10
. After assembly is complete, wheel to
spindle end pla
y should be .000-.003" (.00-.08 mm).

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 17 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Removing Front Rotor (B2300, B3000 & B4000 With Manual Locking Hubs)
Courtesy of FORD MOTOR CO.
Removal & Installation (Except B2300, B3000 & B4000)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with
brake hose connected. See FRONT DISC BRAKE CALIPER
. Wire caliper aside. Remove rotor-to-hub
screws (if equipped). 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
. To install, reverse removal
procedure.
REAR DISC BRAKE PADS
Removal & Installation (Miata & Protege)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove manual adjustment gear
concealment plug from caliper. See Fig. 11
. Insert an appropriate size Allen wrench through hole and
turn manual adjustment gear counterclockwise to retract caliper piston.
2. Remove lower guide bolt from caliper. Rotate caliper upward and wire side. Remove "M" spring.
Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm). To
install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch
rotor. Turn manual ad
justment gear back 1/3 turn.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 18 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Exploded View Of Rear Disc Brake Assembly (Miata & Protege Shown; MX-6 & 626 Are
Similar)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (Millenia)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder reservoir. Raise and support rear of vehicle.
2. Remove rear wheel assemblies. Remove lower guide bolt from caliper. See Fig. 12
. Rotate caliper
upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates. Replace pads
if lining thickness is less than .08" (2.0 mm).
3. 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.
Removal & Installation (MPV & 929)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove upper guide bolt from caliper.
See Fig. 12
. Rotate caliper downward and support using wire. Remove "V" spring. Remove pads, shims
and
guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 19 © 2005 Mitchell Repair Information Company, LLC.

2. To install, reverse removal procedure. Use Disc Brake Expander (49-022 1-600C) and an old pad to push
piston fully inward to install disc pads.
Fig. 12: Exploded View Of Rear Disc Brake Assembly (MPV & 929)

Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-3)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove upper caliper mounting bolt.
See Fig. 13
. Rotate caliper downward. Remove "V" spring, brake pads, shims and guide plates. Replace
brake pads if pad lining thickness is less than .04" (1.0 mm).
2. To install, reverse removal procedure. Using Brake Piston Wrench (49 FA18 602), turn wrench clockwise
until piston bottoms out in brake caliper.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 20 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Exploded View Of Rear Disc Brake Assembly (MX-3)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-6 & 626)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect
parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See
Fig. 11
. Insert an appropriate size Allen wrench through hole and turn manual adjustment gear
counterclockwise to retract caliper piston.
2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove "M"
springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).
3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly
touch rotor. Turn manual ad
justment gear back 1/3 turn.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Removal & Installation (RX7)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove lower guide bolt from caliper.
Rotate caliper upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates.
Replace pad if lining thickness is less than .04" (1.0 mm).
2. To install, reverse removal procedure. Use Disc Brake Piston Wrench (49-FA18-602) to rotate piston
clockwise to install disc pads. Ensure grooves in piston are aligned. See Fig. 14
.
Fig. 14: Aligning Brake Caliper Piston (RX7)

Courtesy of MAZDA MOTORS CORP.
REAR BRAKE CALIPER
Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 626 & 929)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. On all models except MPV and 929,
release parking brake and disconnect parking brake cable from caliper. On all models, disconnect brake
hose from caliper.
2. On Miata, MX-6, Protege and 626, remove manual adjustment gear concealment plug from caliper. See
Fig. 11
. Insert an appropriate size Allen wrench through hole and turn manual adjustment gear
counterclockwise to retract caliper piston.
3. On all models, remove guide bolts from caliper. Remove brake caliper from caliper mount. To install,
reverse removal procedure. Bleed air from system.
Removal & Installation (Millenia)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

caliper. Remove rear brake pads. See REAR DISC BRAKE PADS. Remove remaining caliper guide
bolt. Remove brake caliper from caliper mount. To install, reverse removal procedure. Bleed air from
system.
Removal & Installation (MX-3)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect
parking brake cable from caliper. Disconnect brake flexhose from caliper. See Fig. 13
.
2. Remove upper caliper mounting bolt. Rotate caliper downward. Remove "V" spring, pads, shims and
guide plates. Replace brake pads if pad lining thickness is less than .04" (1.0 mm).
3. Remove lower caliper mounting bolt. Pull caliper toward center of vehicle to slide it off of caliper mount.
To install, reverse removal procedure. Using Brake Piston Wrench (49 FA18 602), turn wrench clockwise
until piston bottoms out in brake caliper. Bleed air from system.
REAR BRAKE ROTOR
Removal & Installation (Miata, Millenia, MPV, MX-3, MX-6, Protege, RX7, 626 & 929)
1. Raise and support vehicle. Remove rear wheel assemblies. Remove rear brake caliper with brake hose
connected. See REAR BRAKE CALIPER
. Support caliper using wire. Remove rotor-to-hub screws (if
equipped). 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
.
3. To install, reverse removal procedure. Check end play at grease cap. On 929, if end play
exceeds .004" (.10 mm), check lock nut torque or replace wheel bearings. On all other models, if end play
exceeds .002" (.05 mm), check lock nut torque or replace wheel bearings.
REAR BRAKE SHOES & WHEEL CYLINDERS
Removal (B2300, B3000 & B4000)
1. Raise and support vehicle. Remove rear wheel assemblies. Remove brake drum. Machine or replace drum
as necessary if inner diameter is not as specified. See DRUM BRAKE SPECIFICATIONS
.
2. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage adjusting lever from adjusting
screw by pulling backwards on self adjuster cable. See Fig. 15
.
3. Move outboard side of adjusting screw upward and back off pivot nut as far as possible. Pull adjusting
lever, cable and adjusting lever spring down and toward rear to unhook pivot hook from large hole in
secondary shoe. DO NOT pry pivot hook from hole.
4. Remove adjusting lever spring and adjusting lever. Remove secondary shoe-to-retracting spring. Remove
primary shoe-to-retracting spring. Unhook cable anchor and remove anchor pin plate.
5. Note color and position of shoe hold-down springs for reassembly. Remove cable guide, shoe hold-down
springs, brake shoes, adjusting screw, pivot nut and socket. Remove parking brake link spring and link.
6. Disconnect parking brake cable from lever. Remove secondary shoe. Disassemble parking brake lever
from shoe by removing retaining clip and spring washer. See Fig. 16
. Remove brake cylinder-to-shoe
connectin
g links. Disconnect brake line from brake cylinder. Remove brake cylinder.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

Installation
1. To install, reverse removal procedure. Clean and sand brake shoe contact points on backing plate. Apply
a light coating of lithium base grease to brake shoe contact points on backing plate. Lubricate adjusting
screw, pivot nut and socket.
2. Install primary and secondary shoes in original positions. Adjust brake shoes. See REAR BRAKE
SHOES ADJUSTMENT . Bleed air from system.
Fig. 15: Identifying Rear Brake Assembly Components (B2300, B3000 & B4000)

Courtesy of FORD MOTOR CO. NOTE: Socket end of adjusting screw assembly and adjusting lever are marked with an
"R" or "L" for reassembly onto proper side of vehicle. Interchanging adjusting
screw assembly and adjusting lever from one side of vehicle to other will cause
brake shoes to retract when automatic adjuster is operated.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 24 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Exploded View Of Rear Drum Brake Assembly (B2300, B3000 & B4000)
Courtesy of MAZDA MOTORS CORP.
Removal (MX-3, MX-6, Protege & 626)
1. Raise and support vehicle. Remove rear wheel assemblies. Remove brake drum. Machine or replace drum
as necessary if inner diameter is not as specified. See DRUM BRAKE SPECIFICATIONS
.
2. Remove return springs, hold pins and springs, and anti-rattle spring. See Fig. 17
. Note positions of
primary and secondary shoes and remove brake shoes. Minimum brake shoe lining thickness is .04" (1.0
mm).
3. Remove stopper spring and clip (if equipped), and return spring. Release parking brake and disconnect
parking brake cable. Remove operating lever assembly. Using Flare Nut Wrench (49-0259-770B),
disconnect brake line from wheel cylinder. Remove wheel cylinder.
Installation
1. To install, reverse removal procedure. Apply lithium base grease to wheel cylinder and anchor sliding
parts, ad
juster threads and shoe contact points on backing plate.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 25 © 2005 Mitchell Repair Information Company, LLC.

2. Install primary and secondary shoes in original positions (secondary shoe is longer). Adjust brake shoes.
See REAR BRAKE SHOES ADJUSTMENT
. Bleed air from system.
Fig. 17: Exploded View Of Rear Drum Brake Assembly (MX
-3 & Protege Shown; MX-6 & 626 Are
Similar)
Courtesy of MAZDA MOTORS CORP.
PARKING BRAKE SHOES
Removal (Millenia, MPV & 929)
Raise and support vehicle. Remove rear wheel assemblies. Remove service plug. See Fig. 18 . Remove brake
caliper with brake hose connected. Support caliper usin
g wire. Remove brake rotor. Remove return springs,

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 26 © 2005 Mitchell Repair Information Company, LLC.