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Brake Pads

REMOVAL & INSTALLATION

Fig. 1: Exploded view of typical front brake pad components

Fig. 2: Exploded view of the rear disc brake pad components

1990–94 323, 626, MX3, MX6 and Protege
FRONT

Fig. 3: Loosen the lower guide pin . . .

Fig. 4: . . . then remove it from the caliper

Fig. 5: Rotate the caliper upwards to access the pads

Fig. 6: The pads can now be removed from the caliper mounting support

Fig. 7: Remove and inspect the guide plates. Replace if damaged

Fig. 8: Before installing the pads, seat the caliper piston into its bore

  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the appropriate tire and wheel assemblies.
  4. If equipped with 1 lower caliper mounting bolt, remove the caliper lower mounting bolt and pivot the caliper up and support it. If equipped with 2 caliper mounting bolts, remove both and support the caliper with mechanics wire. Do not kink the brake line or allow the caliper to hang by the brake line.
  5. Remove the brake pads, shims and if so equipped, pins. Take note of positioning to aid installation.
  6. If the caliper is single piston design, push the caliper back into the bore with a C-clamp or other suitable tool. If the caliper is a 4 piston type caliper, use Mazda tool 49-0221-600C or equivalent and the old inner brake pad, push the caliper piston(s) into the caliper bore.

    To install:

  7. Install the brake pads and shims to the caliper support. Install the caliper over the brake pads.

    NOTE: Be careful that the piston boot does not become caught when lowering the caliper onto the support. Do not twist the brake hose during caliper installation.

  8. Install the caliper mounting bolt(s).
  9. Install the tire and wheel assemblies.
  10. Lower the vehicle and test the brakes for proper operation.
REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the appropriate tire and wheel assemblies. Loosen the parking brake cable adjustment from inside the vehicle.
  4. Disconnect the parking brake cable from the cable bracket and the operating lever.
  5. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads. Do not allow the caliper to hang by the brake line.
  6. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.

    To install:

  7. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.

    NOTE: Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  8. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 12–17 ft. lbs. (16–23 Nm). Attach the parking brake cable to the operating lever and tighten the locknut to 12–17 ft. lbs. (16–23 Nm).
  9. Start the engine and forcefully depress the brake pedal 5–6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  10. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  11. Install the tire and wheel assemblies. Lower the vehicle.
  12. Test the brakes for proper operation.
1995–98 Protege
FRONT
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the appropriate tire and wheel assemblies.
  4. Remove the spring and the pin.
  5. Remove the two pad pins from the brake pads.
  6. Remove the brake pads and shim. Take note of positioning to aid installation.
  7. Push the caliper piston into the caliper bore.

    To install:

  8. Install the brake pads and shims to the caliper.
  9. Insert the pad pins and spring.
  10. Install the tire and wheel assemblies.
  11. Lower the vehicle and test the brakes for proper operation.
REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the wheels. Loosen the parking brake cable adjustment from inside the vehicle.
  4. Disconnect the parking brake cable from the cable bracket and the operating lever. Remove the screw plug. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston inward (turn until it stops).
  5. Remove the upper caliper mounting bolt and pivot the caliper upward off of the pads.
  6. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.

    To install:

  7. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.

    NOTE: Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  8. Lubricate and install the bottom caliper mounting bolt. Tighten the bolt to 33–44 ft. lbs. (46–60 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 9–11 ft. lbs. (12–15 Nm).
  9. Start the engine and forcefully depress the brake pedal 5–6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  10. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  11. Install the tire and wheel assemblies. Lower the vehicle.
  12. Test the brakes for proper operation.
1995 MX3
FRONT
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the appropriate tire and wheel assemblies.
  4. Remove the spring and the pin.
  5. Remove the two pad pins from the brake pads.
  6. Remove the brake pads and shim. Take note of positioning to aid installation.
  7. Using Mazda tool 49-0221-600C or equivalent and the old inner brake pad, push the caliper piston into the caliper bore.

    To install:

  8. Install the brake pads and shims to the caliper.
  9. Insert the pad pins and spring.
  10. Install the tire and wheel assemblies.
  11. Lower the vehicle and test the brakes for proper operation.
REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the wheels. Loosen the parking brake cable adjustment from inside the vehicle.
  4. Disconnect the parking brake cable from the cable bracket and the operating lever. Remove the screw plug.
  5. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads. Do not allow the caliper to hang by the brake line.
  6. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.

    To install:

  7. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.

    NOTE: Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  8. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 12–17 ft. lbs. (16–24 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 105–138 inch lbs. (12–16 Nm).
  9. Start the engine and forcefully depress the brake pedal 5–6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  10. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  11. Install the tire and wheel assemblies. Lower the vehicle.
  12. Test the brakes for proper operation.
1995–98 626 and MX6
FRONT
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the appropriate wheel assemblies.
  4. Remove the caliper lower mounting bolt and pivot the caliper up and support it. Do not kink the brake line.
  5. Remove the brake pads, shims and pin. Take note of positioning to aid installation.
  6. Using Mazda tool 49-0221-600C or equivalent and the old inner brake pad, push the caliper piston into the caliper bore.

    To install:

  7. Install the brake pads and shims to the caliper support. Install the caliper over the brake pads.

    NOTE: Be careful that the piston boot does not become caught when lowering the caliper onto the support. Do not twist the brake hose during caliper installation.

  8. Install the caliper mounting bolt and torque to 22–29 ft. lbs. (30–40 Nm).
  9. Install the tire and wheel assemblies.
  10. Lower the vehicle and test the brakes for proper operation.
REAR
  1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than 1⁄2 full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir.
  2. Raise the vehicle and support safely.
  3. Remove the appropriate tire and wheel assemblies. Loosen the parking brake cable adjustment from inside the vehicle.
  4. Disconnect the parking brake cable from the cable bracket and the operating lever. Remove the screw plug.
  5. Remove the upper caliper mounting bolt and pivot the caliper downward off of the pads. Do not allow the caliper to hang by the brake line.
  6. Remove the brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation.

    To install:

  7. Install the brake pads, shims and spring clips to the caliper support. Pivot the caliper over the brake pads.

    NOTE: Be careful that the piston boot does not become caught when pivoting the caliper onto the support. Do not twist the brake hose during caliper installation.

  8. Lubricate and install the top caliper mounting bolt. Tighten the bolt to 26–28 ft. lbs. (35–39 Nm). Attach the parking brake cable to the operating lever and tighten the screw plug to 105–138 inch lbs. (11.8–15.6 Nm).
  9. Start the engine and forcefully depress the brake pedal 5–6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required.
  10. Check the disc brake drag by applying the brakes several times and then rotating the wheels to check for excessive dragging.
  11. Install the tire and wheel assemblies. Lower the vehicle.
  12. Test the brakes for proper operation.
1995–98 Millenia
FRONT
  1. Raise and safely support the vehicle.
  2. Remove the wheels.
  3. Remove the bottom caliper lock pin and swing the caliper upwards.
  4. Remove the V-springs and remove the pads and shims.
  5. Press the caliper pistons back into their cylinders. Installation is the reverse of removal. Torque the lock pin to 47–62 ft. lbs. (63–84 Nm). Bleed the brake system if necessary.
REAR
  1. Raise and safely support the vehicle.
  2. Remove the wheels.
  3. Remove the lock pin and rotate the caliper upwards.
  4. Remove the V-springs and remove the pads. Remove the shims from the pads.
  5. Press the caliper piston back into the cylinder. Installation is the reverse of removal. Torque the lock pin to 37–50 ft. lbs. (50–68 Nm). Bleed the brake system if necessary.

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