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Disc: Removal & Installation Mazda 6 GG

Mechanical - Hydraulic 16 illustrations ~1178 words

REMOVAL & INSTALLATION

WARNINGAsbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury.
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. Failure to follow these instructions may result in personal injury.
WARNINGWhenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury.
CAUTIONDo not allow the brake master cylinder degas bottle to run dry during the bleeding operation. Keep the brake master cylinder degas bottle 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.
  1. For models with an interlock cable unit, remove the lock unit with the brake switch.
  2. Remove components in the order indicated in the illustration. (Scheme 1) NOTE: Brake Switch Installation Note Fix the brake switch on the brake pedal bracket or interlock cable unit by pressing down at 11 lbs. of force. (Scheme 2) Rotate the brake switch 45° counterclockwise (without interlock cable unit) or clockwise (with interlock cable unit). Verify that the brake switch is locked securely. With the brake pedal in its original position, install the brake switch connector.
  3. Install in the reverse order of removal. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000).

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2
  1. Raise and support front of vehicle. Remove front wheel assemblies. Remove in the order indicated in the illustration. (Scheme 3) NOTE: Mark the wheel hub bolt and disc plate before removal for reference during installation. (Scheme 4)
  2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164523-S20181448702004080900000).
  3. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000). NOTE: Remove any rust or grime on the contact face of the disc plate and wheel hub. Install the disc plate and align the marks made before removal. Push the piston fully inward using the Caliper Piston Expander (49-0221-600C). (Scheme 5) Install the disc pad.

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Note. Brake rotor is also referred to as disc plate.

  1. Raise and support front of vehicle. Remove front wheel assemblies. Remove in the order indicated in the illustration. (Scheme 3) NOTE: It is not necessary to remove the disc plate to remove caliper. If disc plate is removed, mark the wheel hub bolt and disc plate before removal for reference during installation. (Scheme 4)
  2. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000). NOTE: Remove any rust or grime on the contact face of the disc plate and wheel hub. If disc plate was removed, install the disc plate and align the marks made before removal. NOTE: Push the piston fully inward using the Caliper Piston Expander (49-0221-600C). (Scheme 5) Install the disc pads.
  1. Raise and support front of vehicle. Remove front wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 6)
  2. Replace pad if lining thickness is less than specified. See «DISC BRAKE SPECIFICATIONS»(ref-164523-S20181448702004080900000).
  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. (Scheme 5) Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000).

Scheme 6

Scheme 6
Scheme 6
  1. Remove the battery and battery tray.
  2. Remove components in the order indicated in the illustration. (Scheme 7) NOTE: Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid.
  3. Install in the reverse order of removal. On master cylinder installation, see «Master Cylinder Installation Note»(ref-164523-S41488521142004080900000). Tighten components to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000).

Scheme 7

Scheme 7
Scheme 7

Master Cylinder Installation Note

CAUTIONIf the master cylinder is installed at a slanted angle to the power brake unit, the master cylinder piston may jam against the push rod retainer of the power brake unit, causing improper air bleeding, brake drag or other malfunctions. Be sure to install the master cylinder at a level, perpendicular angle to the power brake unit.

Note. Always install the gasket of the power brake unit push rod before performing measurement inspections or adjustments.

  1. Install the Adjustment Gauge (49-G043-001) on to the power brake unit. (Scheme 8) Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000).
  2. Using a vacuum pump, apply 19.7 in. Hg (66.7 kPa) of vacuum. (Scheme 9)
  3. Measure the dimension of "L" as shown in the illustration. (Scheme 8) Specification 1.020-1.027" (25.9-26.1 mm).
  4. If dimension "L" is not within the specification as shown, remove adjustment gauge and use Adjustment Gauge Wrench (49-B043-004) to adjust the length of the push rod while using Adjustment Gauge Rod (49-E043-003A) to keep the push rod from rotating. (Scheme 10)
  5. Remove the adjustment gauge wrench and adjustment gauge rod, replace adjustment gauge and measure dimension "L" again. If incorrect readjust push rod depth.
  6. Install the master cylinder to the power brake unit. CAUTION: If after installing the master cylinder, air does not bleed properly from the brake lines even after performing air bleeding, brake drag occurs or other characteristics are present, it is possible that the master cylinder piston is jammed against the power brake unit. If air cannot be bled properly, brake drag exists or other malfunctions occur, remove the master cylinder and reinstall properly.

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Remove the console. See «CONSOLE»(ref-164523-S14052853522004081200000) under MISCELLANEOUS.
  2. Remove the rear seat cushion.
  3. Remove the exhaust pipe. Remove the exhaust pipe insulator.
  4. Remove components in the order indicated in the illustration. (Scheme 11)
  5. To install, reverse removal procedure.
  6. Adjust the parking brake stroke. See «PARKING BRAKE»(ref-164523-S27842162392004080900000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system if necessary. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000).

Scheme 11

Scheme 11
Scheme 11
  1. Remove master cylinder. See «MASTER CYLINDER»(ref-164523-S26791805472004080900000).
  2. Remove the windshield wiper arm and blade. Remove the cowl grille. Remove the windshield wiper motor. Remove the cowl panel. See appropriate WIPER/WASHER SYSTEMS article in ACCESSORIES & EQUIPMENT.
  3. Remove in the order indicated in the illustration. (Scheme 12)
  4. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164523-S32092995872004080900000).

Scheme 12

Scheme 12
Scheme 12
  1. Raise and support vehicle. Remove rear wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 13) NOTE: It is not necessary to remove the disc plate to remove caliper.
  2. To install, reverse removal procedure. For disc pad installation see, «REAR DISC BRAKE PADS»(ref-164523-S23652646162004080900000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). After installation, depress the pedal several times, rotate the wheel by hand, and verify that the, brake does not drag. NOTE: Remove any rust or grime on the contact face of the disc plate and wheel hub. If disc plate was removed, install the disc plate.

Scheme 13

Scheme 13
Scheme 13
  1. Raise and support vehicle. Remove rear wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 13)
  2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164523-S20181448702004080900000).
  3. To install, reverse removal procedure. For disc pad installation see, «REAR DISC BRAKE PADS»(ref-164523-S23652646162004080900000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). After installation, depress the pedal several times, rotate the wheel by hand, and verify that the, brake does not drag.
  1. Raise and support rear of vehicle. Remove rear wheel assemblies.
  2. Remove in the order indicated in the illustration. (Scheme 14)
  3. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164523-S01016168842004080900000). To install disc pads compress the caliper piston with a Caliper Piston wrench (49-FA18-602). (Scheme 15) Ensure that the piston is fully depressed into the caliper assembly.

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Disconnect the negative battery cable.
  2. For MTX vehicle, remove the shift lever knob. Remove the panel No. 1 using a tape-wrapped screwdriver. (Scheme 16)
  3. Remove the panel No. 2 using a tape-wrapped screwdriver, disconnect the cigarette lighter connector, and remove the front ashtray illumination.
  4. Remove the bolts. Disconnect the accessory socket connector.
  5. To install, reverse removal procedure.

Scheme 16

Scheme 16
Scheme 16

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