Conventional Brake System: Removal & Installation Mazda MX-5 NC

BRAKE PEDAL REMOVAL/INSTALLATION

Note. When the brake switch connector is connected to the brake switch, the clearance between the pedal and the brake switch is adjusted automatically. However, this mechanism will only function one time.

Scheme 18

1. Remove in the order indicated in (Scheme 18).
2. Install in the reverse order of removal.

Brake Pedal Removal Note

1. Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.
2. Remove the brake pedal.

Scheme 19

1. Install the new brake switch to the brake pedal (MT) or the interlock cable (AT), and secure it by turning it clockwise 45° (AT) or counterclockwise 45° (MT).

Brake Switch Connector Installation Note

1. Inspect the brake pedal. (See «BRAKE PEDAL INSPECTION»(ref-244464-S11006378782006092400000) .)
2. With the brake pedal in its original position, install the brake switch to the brake switch connector.

Master Cylinder Installation Note

Scheme 20

Scheme 21

Scheme 22

1. Install the SST to the power brake unit and tighten to the specified torque. Tightening torque 13.7-21.6 N.m {1.4-2.2 kgf.m, 10.2-15.9 ft.lbf}
2. Apply a vacuum of 66.7 kPa {500 mmHg, 19.7 inHg} to the power brake unit using a vacuum gauge. NOTE: Use any commercially available vacuum gauge.
3. Using calipers, measure dimension L (Scheme 22) Standard L dimension 30.4-30.6 mm {1.197-1.204 in}
4. If dimension L is not within the standard, remove the SST (49 G043 001) and, while stopping the push rod rotation with the SST (49 E043 003A), adjust the push rod length with the SST (49 B043 004).
5. Switch the SSTs and remeasure dimension L.
6. Install the master cylinder to the power brake unit.

Scheme 23

Scheme 24

1. Disconnect the brake fluid level sensor connector from the master cylinder.
2. Inspect for continuity according to fluid level between the brake fluid level sensor terminals. If not as indicated in (Scheme 24), replace the reserve tank.

Disc Plate Installation Note

1. Remove any rust or foreign material from the wheel hub and disc plate.
2. Align the marks made before removal and install the disc plate to the wheel hub.

Scheme 25

1. Clean the exposed area of the piston.
2. Rotate the piston clockwise slowly using the SST and push the piston completely until the piston grooves are in the position (Scheme 26)
3. Install the caliper.

Scheme 26

1. After installing the parking brake cable, verify that the operating lever returns to the stopper nut with the parking brake lever released.

Scheme 27

1. Remove in the order indicated in (Scheme 28).
2. Install in the reverse order of removal.
3. After installation, depress the brake pedal a few times, and inspect the following. The disc pad projection is securely installed to the piston groove Parking brake lever stroke Brake drag

Scheme 28

1. Clean the exposed area of the piston.
2. Rotate the piston clockwise slowly using the SST and push in the piston completely until the piston grooves are in the position (Scheme 29)
3. Install the caliper.

Scheme 29

1. Disassemble in the order indicated in (Scheme 30).
2. Assemble in the reverse order of disassembly.

Scheme 30

1. Rotate the piston counter-clockwise using the SST , remove the piston from the caliper body.

Scheme 31

Scheme 32

1. Assemble the dust seal to the piston.
2. Assemble the lip of the dust seal to the groove of the caliper body with the dust seal is assembled to the piston (Scheme 32)
3. Rotate the piston clockwise using the SST slowly and push the piston inwards completely.
4. Verify that the dust seal is installed into the groove of the piston securely.