Disc & Drum: Removal & Installation Mazda MX-6 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 Expander (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. Wire caliper aside. 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. To install, reverse removal procedure.

Scheme 2

1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. (Scheme 2) Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.
2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove "M" springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than.04" (1.0 mm).
3. To install, reverse removal procedure. 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. Release parking brake and disconnect parking brake cable from caliper. Disconnect brake hose from caliper.
2. Remove manual adjustment gear concealment plug from caliper. (Scheme 2) Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston.
3. Remove lower guide bolt from caliper. Rotate caliper upward. Pull caliper toward center of vehicle to slide it off of caliper mount. To install, reverse removal procedure. Bleed air from system.

1. Raise and support vehicle. Remove rear wheel assemblies. Remove rear brake caliper with brake hose connected. 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 table.
3. To install, reverse removal procedure. Check end play at grease cap. If end play exceeds .002" (.05 mm), check lock nut torque or replace wheel bearings.

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. Remove return springs, hold pins and springs, and anti-rattle spring. (Scheme 3) Note positions of primary and secondary shoes and remove brake shoes. Minimum brake shoe lining thickness is.04" (1 mm).
3. Remove stopper spring and clip (if equipped), and return spring. Release parking brake and disconnect parking brake cable. Remove operating lever assembly. 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). Adjust brake shoes. see scheme 1 See REAR BRAKE SHOES under ADJUSTMENTS. Bleed air from system.

Scheme 3

Disconnect fluid level sensor electrical connector. (Scheme 4) 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. To install master cylinder, reverse removal procedure. Bleed air from system.

Scheme 4

Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL & INSTALLATION. Disconnect vacuum line at power brake unit. (Scheme 5) 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 5