Disc: Removal & Installation Mazda MX-5 NB

Removal & Installation

Raise and support 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. Bleed air from system.

1. Raise and support vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See «FRONT DISC BRAKE CALIPER»(ref-2891-S28205266522000041400000) . 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-2891-S07667694372000041400000) table. To install, reverse removal procedure.

Scheme 1

1. Raise and support vehicle. Remove rear wheel assemblies. Remove plug, cap and lock bolt. Remove spring. (Scheme 1)
2. Remove pads, shims, and guide plates. Replace pad if lining thickness is less than.04" (1.0 mm). To install, turn manual adjustment gear counterclockwise with Allen wrench to retract caliper piston. Install disc pads. Turn manual adjustment gear clockwise until pads just touch rotor. Turn adjustment gear back 1/3 turn. To complete installation, reverse removal procedure.

Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from 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.

1. Raise and support vehicle. Remove rear wheel assemblies. Disconnect parking brake cable. Remove rear brake caliper with brake hose connected. See «REAR BRAKE CALIPER»(ref-2891-S18026806292000041400000) . 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-2891-S07667694372000041400000) table. To install, reverse removal procedure.

Disconnect fluid level sensor electrical connector at fluid reservoir. Remove brake pipe, connector bolt, nut and washer and connector bracket. Remove proportioning by-pass valve and bracket. Remove master cylinder. On ABS models, remove "O" ring. To install master cylinder, reverse removal procedure. Bleed air from system.

Remove master cylinder and proportioning by-pass valve from power brake unit. See MASTER CYLINDER . Disconnect vacuum line at power brake unit. From inside vehicle, remove snap pin and clevis pin. Separate push rod from brake pedal. Remove power brake unit-to-firewall nuts. Remove power brake unit and gasket. To install, reverse removal procedure. Bleed air from system.