Disc & Drum: Removal & Installation Mazda MPV I

Removal & Installation

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. (Scheme 1) Pivot caliper upward and support using rope. 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) table.
2. To install, reverse removal procedure. Use Disc Brake Expand Tool (49-0221-600C) and an old pad to push piston fully inward to install disc pads.

Scheme 1

MINIMUM PAD LINING SPECIFICATIONS

Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS under REMOVAL & INSTALLATION. Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system.

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. Support caliper using rope. Remove grease cap (if equipped). 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 table at end of this article. To install, reverse removal procedure.

Removal

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 table.
2. Release parking brake and disconnect parking brake cable. Note positions of primary and secondary hold springs and remove hold springs. Remove adjust lever, link, pull-off spring, shoe spring, return springs, and adjuster. (Scheme 2) Note positions of primary and secondary shoes and remove brake shoes. Minimum brake shoe lining thickness is.04" (1 mm).
3. Remove parking brake strut. Using Flare Nut Wrench (49-0259-770B), disconnect brake line from wheel cylinder. Remove wheel cylinder.

Installation

1. To install, reverse removal procedure. Apply brake grease to wheel cylinder and anchor sliding parts, adjuster threads and shoe contact points on backing plate.
2. Install primary and secondary shoes in original positions (secondary shoe is longer). Install primary (Yellow) and secondary (White) hold springs in original positions. Adjust brake shoes. See REAR BRAKE SHOES under ADJUSTMENTS. Bleed air from system.

Scheme 2

Disconnect fluid level sensor electrical connector. (Scheme 3) Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. Remove nuts attaching master cylinder to firewall or power brake unit. Remove master cylinder from vehicle.

1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.
2. Invert adjuster gauge and place it on power brake unit. Adjust push rod on power brake unit until there is no clearance between push rod and adjuster gauge screw. To install master cylinder, reverse removal procedure. Bleed air from system.

Scheme 3

Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL & INSTALLATION. Disconnect vacuum line at power brake unit. (Scheme 4) From inside vehicle, remove cotter pin and clevis pin. Separate push rod from brake pedal. Remove power brake unit-to-firewall nuts. Remove power brake unit. To install, reverse removal procedure. Bleed air from system.

Scheme 4