Disc & Drum: Removal & Installation Mazda MPV II

Removal & Installation

1. Raise and support front of vehicle. Remove front wheel assemblies. Remove flexible hose. Remove lower lock pin/guide bolt. Pivot caliper upward, and wire aside.
2. Remove pads, shims, guide plates or pad guides and "V" springs or "M" springs (if equipped). (Scheme 1)or (Scheme 2). Replace pad if lining thickness is less than specified. See «MINIMUM PAD LINING SPECIFICATIONS (FRONT)»(ref-127905-S24477827112001103000000) table.
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. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000).

Scheme 1

Scheme 2

MINIMUM PAD LINING SPECIFICATIONS (FRONT)

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 . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .

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»(ref-127905-S29431394692001103000000) . 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»(ref-127905-S13362582822001103000000) table. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000) .

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. (Scheme 3) Rotate caliper upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates. Replace pads if lining thickness is less than 0.08" (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. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000).

Scheme 3

Scheme 4

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove manual adjustment gear concealment plug from caliper. (Scheme 4) Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.
2. Remove lock bolt from caliper. Rotate caliper upward and wire side. Remove "M" spring. Remove disc pad, shims and guide plates. Replace pad if lining thickness is less than.039" (1.0 mm). To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000). Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from caliper. Remove snap ring, dust seal, piston seal and piston. (Scheme 5) Remove bleeder cap and screw. Remove caliper body. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-127905-S04569776762001103000000).

Scheme 5

Removal & Installation (Protege & 626)

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Disconnect brake hose from caliper.
2. Remove dust seal. Remove piston. Remove manual adjustment gear from caliper. (Scheme 6) Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.
3. Remove snap ring, adjusting bolt, "O" ring, connecting link and piston seal. Remove spring, operating lever and boot. Remove bleeder cap and screw. Remove boot. Remove caliper body. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-127905-S04569776762001103000000).

Scheme 6

1. Raise and support vehicle. Remove rear wheel assemblies. Remove rear brake caliper with brake hose connected. See «REAR BRAKE CALIPER»(ref-127905-S33897527792001103000000) . 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»(ref-127905-S13362582822001103000000) table.
3. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000) . Check end play at grease cap.

Removal

1. Raise and support vehicle. Remove rear wheel assemblies. Remove screw. Remove brake drum. Machine or replace drum as necessary if inner diameter is not as specified. See «DRUM BRAKE SPECIFICATIONS»(ref-127905-S30630974192001103000000) table.
2. Remove upper and lower return springs, hold pins and springs, and anti-rattle spring. (Scheme 7), (Scheme 8) or (Scheme 9). Note positions of primary and secondary shoes and remove brake shoes. Minimum brake shoe lining thickness is.039" (1.0 mm).
3. Remove return spring. Release parking brake and disconnect parking brake cable. Remove operating lever component. Remove ABS wheel sensor. Remove Brake pipe. Using Flare Nut Wrench (49-0259-770B), disconnect brake line from wheel cylinder. Remove wheel cylinder and gasket. Remove dust boot. Remove hub cap and lock nut. Remove wheel hub component. Remove backing plate.

Scheme 7

Scheme 8

Scheme 9

Installation

1. To install, reverse removal procedure. Apply lithium base 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). Adjust brake shoes. See «REAR BRAKE SHOES»(ref-127905-S29570573972001103000000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000) . Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-127905-S04569776762001103000000) .

Raise and support vehicle. Remove rear wheel assemblies. Remove service plug. (Scheme 10) Remove brake caliper with brake hose connected, and wire aside. Remove disc plate. Remove upper and lower return springs, hold springs and pins. Remove parking brake shoes. Minimum parking brake shoe lining thickness is.039" (1.0 mm). Remove adjuster and operating lever.

To install, reverse removal procedure. Apply lithium base grease to anchor sliding plate, adjuster threads and shoe contact points on backing plate. Set marked side (with arrow) of operating lever to front side. Ensure threaded side of adjuster faces forward on left wheel and rearward on right wheel. Adjust parking brake shoes. See PARKING BRAKE SHOES under ADJUSTMENTS. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .

Scheme 10

Disconnect fluid level sensor electrical connector at fluid reservoir. (Scheme 11) Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. Remove nuts attaching master cylinder to power brake unit. Remove connector, bolt and washers. Remove proportioning bypass valve (PBV) and "O" ring. Remove master cylinder from vehicle. To install master cylinder, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Bleed air from system. See BLEEDING BRAKE SYSTEM.

Scheme 11

1. Remove brake fluid level sensor connector. (Scheme 11) Remove brake pipe. Remove MTX hose, if equipped. Remove master cylinder. See «MASTER CYLINDER»(ref-127905-S35559882372001103000000). Remove "O" ring (ABS Model). Remove vacuum hose. Remove snap and clevis pin.
2. Remove connector and holder, if equipped. Remove nut and fork. Remove power brake unit. Remove gasket and spacer, if equipped. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-127905-S08504416302001103000000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-127905-S04569776762001103000000).