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Disc: Overhaul Mazda 6 GG

Mechanical - Hydraulic 6 illustrations ~340 words

OVERHAUL

WARNINGUse of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.
WARNINGBrake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTIONDo not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system.
CAUTIONBrake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

Note. When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after components have been correctly reconnected.

Disassembly & Reassembly

  1. Disassemble in the order indicated in the illustration. (Scheme 17) CAUTION: Blow the compressed air slowly to prevent the piston from suddenly popping out.
  2. Place a piece of wood in the caliper, then blow compressed air through the hole to force the piston out of the caliper.
  3. Remove the piston seal from the brake caliper by using the Seal Removal Pick (49-0208-701A). (Scheme 18)
  4. Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000).

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. Disassemble in the order indicated in the illustration. (Scheme 19)
  2. Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000). NOTE: When assembling stop screw (without ABS), install the new O-ring onto the stop screw. (Scheme 20) Then push the primary piston assembly in fully. Install and tighten the stop screw. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). NOTE: When assembling stop pin (with ABS), install the secondary piston with the piston hole facing the stop pin. (Scheme 21) Then install the new O-ring onto the stop pin. Install the stop pin. Push and release the secondary piston assembly to verify that it is held by the stop pin. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000).

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Disassemble in the order indicated in the illustration. (Scheme 22) NOTE: When removing the piston, use the Caliper Piston wrench (49-FA18-602), to remove the piston. see scheme 18
  2. Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000). NOTE: When assembling the piston, use the caliper piston wrench to ensure that the piston is fully depressed into the caliper assembly.

Scheme 22

Scheme 22
Scheme 22

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