1991 MAZDA MIATA brake pads

4. On all models, measure applied pedal height. If distance is not as specified, check brake adjustment or
system for air. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.
BRAKE PEDAL HEIGHT SPECIFICATIONS
TESTING
POWER BRAKE UNIT
1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake
pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal
does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is
operating. If length of strokes is equal, test check valve and vacuum hose between vacuum source and
power brake unit. Repair as necessary, and go to next step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake unit is operating. If pedal height recedes, test check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (Protege & 323)
Raise and support front of vehicle. Remove wheels. Remove spring "A". See Fig. 5 . Remove spring "B".
Remove pad pins. Remove pads, shims and anti-squeak shim. Replace pad if lining thickness is less than
specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE. To install, reverse removal
ApplicationIn. (mm)
Pedal Released
B2200 & B2600i7.1-7.3 (180-185)
Miata, MX-6, 626 & 9296.7-7.1 (171-181)
MPV7.5-7.9 (191-201)
Protege & 3237.6-7.7 (193-196)
RX77.2-7.4 (184-189)
Pedal Applied (1)
B2200 & B2600i4.1 (105)
Miata, MX-6, 626 & 9293.7 (95)
MPV5.2 (133)
Protege & 3232.8 (70)
RX73.9 (100)
(1)Minimum height.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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touch spindle face.
4. Insert screwdriver into slot provided behind pin tabs on inboard side of pin. Using pliers, compress end of
pin while using screwdriver to pry until tabs slip into spindle groove.
5. Place a 7/16" diameter punch on end of pin, and drive caliper pin out of caliper slide groove. Repeat
procedure for lower pin. Remove caliper from rotor. Remove outer brake pad. Compress anti-rattle spring
clip, and remove inner brake pad. Support caliper aside. Replace pad if lining thickness is less than
specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE.
Installation
Use "C" clamp to push caliper piston into piston bore until it bottoms out. To install, reverse removal procedure.
Bleed air from brake system.
Removal & Installation (RX7 With 4-Piston Caliper)
Raise and support front of vehicle. Remove wheels. Remove pad pins and pad springs. See Fig. 6 . Remove
brake pads and shims. Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING
SPECIFICATIONS (FRONT) . To install, reverse removal procedure. CAUTION: During installation, DO NOT tap caliper pin too far into spindle groove. If
this happens, tap pin in other direction until tabs snap back into place.
Tabs on each end of caliper pin must be free to catch on spindle flanks.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Fig. 6: Front Disc Brake Assembly (RX7 with 4-Piston Caliper)
Removal & Installation (All With Single-Piston Caliper)
Raise and support front of vehicle. Remove wheels. Remove lower lock pin/guide bolt. See Fig. 7 , Fig. 8 , Fig.
10 , Fig. 11 , or Fig. 12 . Pivot caliper upward, and support using rope. Remove brake pads. Replace pad if
lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE.
To install, reverse removal procedure.
MINIMUM PAD LINING SPECIFICATIONS (FRONT)
ApplicationThickness In. (mm)
B2200, B2600i & Navajo.12 (3.0)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Fig. 12: View of Front Disc Brake Assembly 929
FRONT DISC BRAKE CALIPER
Removal & Installation
Raise and support front of vehicle. Remove wheel and disconnect brake hose. Plug all openings. Remove brake
disc pads. Remove remaining bolt(s). Remove caliper body from vehicle. To install, reverse removal procedure.
Bleed hydraulic system.
FRONT BRAKE ROTOR
NOTE: For removal and installation of front disc brake caliper for Navajo, see FRONT
DISC BRAKE PADS under REMOVAL & INSTALLATION.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Removal & Installation (B2200 & B2600i 2WD)
1. With caliper assembly removed, remove wheel hub grease cap, cotter pin, lock plate and ring adjusting
lock nut. Remove thrust washer and outer bearing from hub. Slide hub and rotor assembly from spindle.
2. Mark rotor-to-hub position. Separate rotor from hub. Machine rotor if lateral runout exceeds
specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC
BRAKE SPECIFICATIONS at end of article.
3. To install, reverse removal procedure and evenly tighten rotor-to-hub bolts. Adjust wheel bearings.
Removal & Installation (B2600i 4WD) 1) Remove front caliper. Set hub to FREE position. Remove hub
bolts. Remove hub as an assembly. Install 2 bolts and nuts to retain hub assembly together. Remove snap
ring and spacer.
4. Remove set bolt and plate. Remove nut. Remove rotor and hub assembly. Mark rotor-to-hub position.
Remove rotor from hub. Machine rotor if lateral runout exceeds specification. Replace rotor if measured
thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS
at end of
article. To install, reverse removal procedure.
Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 323 & 626)
1. Raise and support front of vehicle. Remove wheel. Remove caliper with brake hose connected. Support
caliper using rope. Remove 2 rotor-to-hub screws. 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
at end of article. To install,
reverse removal procedure.
Removal & Installation (Navajo 2WD)
1. Raise vehicle, and support using safety stands. Remove wheel and caliper assemblies. Remove dust cap,
cotter pin, nut, washer and outer bearing. Carefully remove hub and rotor assembly. Remove inner
bearing and seal.
2. To install, reverse removal procedure. Adjust front wheel bearings. While rotating rotor, tighten adjusting
nut to 17-25 ft. lbs. (23-34 N.m). Back off adjusting nut 120-180 degrees. Install bearing retainer and new
cotter pin.
Removal (Navajo 4WD With Automatic Locking Hubs)
1. Raise vehicle, and support using safety stands. Remove wheel assembly and caliper. See FRONT DISC
BRAKE PADS under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs.
Remove automatic locking hub housing from spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacer. See Fig. 13
. Carefully pull plastic
moving cam off wheel bearing adjusting nut. Remove 2 plastic thrust spacers from adjusting nut. Using a
magnet, remove locking key.
CAUTION: DO NOT pry on plastic cam or spacers during removal as damage
may result. To prevent damaging spindle threads, remove locking
key before removing adjusting nut.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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(T70T-4252-B), remove wheel bearing adjusting nut. Remove outer wheel bearing, and then remove
rotor.
Installation
When installing rotor, outer bearing and adjusting nut, tighten adjusting nut to 35 ft. lbs (47 N.m) to seat
bearings. Spin rotor, and back off adjusting nut 1/4 turn. Tighten adjusting nut to 16 INCH lbs. (1.8 N.m). To
install remaining components, reverse removal procedure. See Fig. 13
. After assembly is complete, wheel to
spindle end play should be .001-.003" (.02-.08 mm).
Removal (Navajo 4WD With Manual Locking Hubs)
1. Raise and support vehicle. Remove wheel assembly and caliper. See FRONT DISC BRAKE PADS
under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs. Remove manual
locking hub housing from spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacer. See Fig. 14
. Using Lock Nut Wrench
(T86T-1197-A), remove outer wheel bearing lock-nut. Remove lock washer. Using Lock Nut Wrench
(T86T-1197-A), remove inner wheel bearing lock nut, outer wheel bearing and rotor. CAUTION: Extreme caution must be used when aligning adjusting nut lug with
spindle locking key slot to prevent damage to locking key. Extreme
caution must be used when aligning fixed cam key with spindle key slot to
prevent damage to fixed cam.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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install remaining components, reverse removal procedure. See Fig. 14. After assembly is complete, wheel to
spindle end play should be .001-.003" (.02-.08 mm).
Removal & Installation (929)
1. Raise and support front of vehicle. Remove wheel. Remove caliper with brake hose connected. Support
caliper with rope. Remove hub cap, wheel bearing lock nut and washer. Remove hub and rotor assembly.
2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than
specified minimum thickness. See DISC BRAKE SPECIFICATIONS
at end of article.
3. To install, reverse removal procedure. Replace wheel bearing lock nut, and tighten to 72-130 ft. lbs. (98-
177 N.m). Check hub end play. If end play exceeds .002" (.05 mm), replace bearing. If end play is within
specification, stake lock nut at groove in axle shaft.
REAR DISC BRAKE PADS
Removal & Installation (Miata, Protege & 323)
1. Raise and support rear of vehicle. Remove wheel. Remove manual adjustment gear concealment plug
from caliper. See Fig. 15
. Insert an appropriate size Allen wrench through hole and turn manual
ad
justment gear counterclockwise to retract caliper piston.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Fig. 15: Rear Disc Brake Assembly (Miata, Protege & 323)
2. Remove lower guide bolt from caliper. Rotate caliper upward, and support using rope. Remove "M"
spring. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).
To install, reverse removal procedure.
Removal & Installation (MX-6 & 626)
1. Raise and support rear of vehicle. Remove wheel. Release parking brake and disconnect parking brake
cable from caliper. Remove upper guide bolt from caliper. Rotate caliper downward and secure with rope.
Remove "V" springs. Remove pads and shims.
2. To install, turn caliper piston clockwise using Disc Brake Piston Wrench (49-FA18-602) to retract caliper
piston. Ensure groove in piston aligns with alignment pin on back of inner pad. Replace pad if lining
thickness is less than .04" (1.0 mm). To complete installation, reverse removal procedure.
Removal & Installation (RX7)
1. Raise and support rear of vehicle. Remove wheel. Remove lower guide bolt from caliper. Rotate caliper
upward, and secure using rope. Remove "V" springs. Remove pads and shims. Replace pad if lining
thickness is less than .04" (1.0 mm).

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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