1992 MAZDA PROTEGE parking brake

P
BRAKING SYSTEM
INDEX ......................................................
OUTLINE .................................................. ;I g
SPECIFICATIONS .................................... P- 3
CONVENTIONAL BRAKING SYSTEM.. ......... P- 4
PREPARATION ....................................... P- 4
TROUBLESHOOTING GUIDE .................... P- 5
AIR BLEEDING .......................................
BRAKE HYDRAULIC LINE.. -
...................... F- t
BRAKE FLUID ........................................
BRAKE PEDAL ....................................... ;I ;
MASTER CYLINDER ................................ P-l 0
POWER BRAKE UNIT .............................. P-13
DUAL PROPORTIONING VALVE.. .............. P-l 6
FRONT BRAKE (DISC) ............................. P-16
CALIPER ............................................... P-21
REAR BRAKE (DISC) ............................... P-23
CALIPER ............................................... P-26
REAR BRAKE (DRUM) ............................. P-28
WHEEL CYLINDER .................................. P-30
PARKING BRAKE SYSTEM ........................ P-31
TROUBLESHOOTING GUIDE .................... P-31
PARKING BRAKE SHOE .......................... P-31
PARKING BRAKE (LEVER TYPE) ............... P-31
PARKING BRAKE CABLE.. ....................... P-32
PARKING BRAKE LEVER ......................... P-33
13UOPX-001

P INDEX
NDEX
LEVER STROKE (WHEN PULLED WITH A FORCE OF 98 N [lo kg, 22 lb])
FMVSS 116, DOT-3,
SAE J1703 OTCHES
1. Brake hydraulic line
Inspection / Removal /
Installation.. ............................... page P- 6
2. Brake pedal
Inspection (on-vehicle).
............... page P- 8
Removal / Inspection /
Installation ................................. page P-l 0
3. Master cylinder
Removal I installation.. ................ page P-10
Disassembly / Inspection /
Assembly .................................. page P-12
4. Power brake unit
Inspection (on-vehicle). ............... page P-l 3
Removal I Installation.. ................ page P-16
5. Dual proportioning valve
Inspection
................................... page P-l 6
Replacement.. ............................. page P-l 7
6. Front brake (disc)
Inspection (on-vehicle). ............... page P-l 8
Replacement.. .............................
page P-l 8
Removal / installation.. ................ page P-l 9
Inspection ...................................
page P-20
7. Caliper
Disassembly I Inspection /
Assembly.. ................................ page P-21
P-2
8. Rear brake (disc)
23UOPX-008
Inspection (on-vehicle) . . . . . . . , , ., . . . . page P-23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-23
Removal / Installation . . . . . . . . . . . . . . . . . . page P-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-25
9. Caliper
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-26
10. Rear brake (drum)
Inspection (on-vehicle). . . . . . . . . . . . . . . . page P-28
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-28
11. Wheel cylinder
Disassembly / Inspection /
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-30
12. Parking brake (lever type)
Inspection (on-vehicle) . . . . . . . . . . . . . . . . page P-31
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-31
13. Parking brake cable
Removal / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-32
14. Parking brake lever
Removal / Inspection / --
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page P-33

OUTLINE
OUTLINE
SPECIFICATIONS
item Specifications
Brake pedal
Master cylinder
Front disc brake
Rear disc brake
Rear drum brake
Power brake unit
Braking force control device
Brake fluid Type Suspended
Pedal lever ratio
I 4.1
I
Max. stroke mm (in) 140 (5.51)
I
Type
Cylinder inner diameter mm (in)
Type
Cylinder bore mm (in)
Pad dimensions (area x thickness)
mm’ (in2) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness) Tandem (with level sensor)
22.22 (0.875)
Ventilated disc (integral)
53.97 (2.12)
13-in wheel: 3,800 (5.89)x 10 (0.39)
14-in wheel: 4,300 (6.66) x 10 (0.39)
13-in wheel: 235 x 22 (9.25 x 0.87)
14-in wheel: 257 x 22 (10.12 x 0.87)
We
I Solid disc (mounting support)
I
Cylinder bore mm (in)
I 30.2 (1.19)
I
Pad dimensions (area x thickness)
mm2 (in’) x mm (in)
Disc plate dimensions mm (in)
(outer diameter x thickness)
Type 2,600 x 8.0 (4.03 x 0.31)
251 x 9 (9.88 x 0.35)
Leading-trailing
Wheel cylinder inner diameter mm (in) 17.46 (0.687)
I
Lining dimensions mm (in)
(width x length x thickness) 35x192.0x4.5 (1.38x7.56x0.18)
I
Drum inner diameter mm (in) 200 (7.9)
I
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
@ : 214 (8.43) @ : 239 (9.41)
Dual proportioning valve
FMVSS 116: DOT-3, SAE: J1703
Type
Diameter
Type mm (in)
Parking brake
Type
Operation system Mechanical two rear wheel control
Center lever I
3 With BP SMTX, B6, @With BP 4EATX
I I
23UOPX-001
P-3

CONVENTIONAL BRAKE SYSTEM
Installation note
Manual adjustment gear
1. Turn the manual adjustment gear clockwise until the brake
pads just touch the disc pIaTe.
2. Return the manual adjustment gear l/3-turn
Removal / Installation
Caliper
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
5. Tighten all nuts and bolts to the specified torques, referring to the figure.
@ 22-29 (2.2-3.0, 16-22)

23-30 (2.2-3.1, 16-
N.m (m-kg, R-lb)
23UOPX-00
1. Parking cable 7. Caliper
Removal I Inspection / Disassembly / Inspection /
Installation . . . . . . . . . . . . . . . . . . . . . . ,.,........ page P-32 Assembly ,.....*........................... page P-26
2. Connecting bolt 8. Disc pad assembly
3. Brake hose Replacement ,...,.,.,.,........*........... page P-23
4. Screw plug Inspection . . . . . . . ..*......................... page P-25
5. Manual adjustment gear 9. Bolt
Removal Note . . . . . . . . . . . . . . . ,,..,.,....... page P-23 10. Mounting support
Installation Note ,....,.,..,.,...,., ,...,., page P-24 11, Disc plate
6. Lock bolt Inspection .,...........*..................... page P-25
After installation:
(1) Add brake fluid and bleed air. (Refer to page P-6.)
(2) Adjust the parking brake lever stroke. (Refer to page P-31 .)
(3) Depress the brake pedal a few times and check that the rear brakes do not drag excessively while
rotating the wheel by hand.
P-24

P CONVENTIONAL BRAKE SYSTEM
REAR BRAKE (DRUM)
Quick Inspection, On-vehicle
1. Jack up the rear of the vehicle and support it with safety
stands.
2. Remove the wheels.
3. Remove the brake drum. (See below)
4. Verify the remaining thickness of the lining.
Thickness: l.Omm (0.04 in) min.
I
1 BUOPX-017
Removal / Inspection / Installation
1. Remove the lining in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
(18.0-24.0, 130-l 74)
N-m (m-kg, R-lb)
371 InPx-fll’
--_-. ,. -. 9
1. Screw
2. Brake drum
Inspection.. . . . . . . . page P-29
Installation Note
. . . . . . . . . . . . . . . . . . . . . . . page P-29
3. Return spring
4. Hold pin and spring
5. Anti-rattle spring
6. Brake shoe (leading side)
Inspection . . . . . . . . . . . . . . Above 7. Brake shoe (trailing side)
Inspection . . . . . . . . . . . . . . . . Above
8. Stopper spring and clip
9. Return spring
10. Parking brake cable
11. Operating lever assembly
12. Brake pipe
Removal Note . . page P-29 13. Bolt
14. Wheel cylinder
Disassembly I Inspection /
Assembly . . . . . . . page P-30
15. Wheel cylinder gasket
16. Hub cap
17. Locknut
18. Wheel hub
19. Backing plate
P-28

P CONVENTIONAL BRAKE SYSTEM
23UOPX-02
WHEEL CYLINDER
Disassembly / inspection / Assembly Caution
Take the following steps after installation:
l Add fluid and bleed the air. (Refer to page P-6.)
l Check for fluid leakage. (Refer to page P-6.)
l Depress the brake pedal a few times and check that
the rear brakes do not drag while rotating the wheel.
l Check the parking brake lever stroke.
(Refer to page P-31.)
Caution
l if a problem is found in the wheel cylinder or the piston, replace the wheel cylinder as an as-
sembly.
1. Disassemble the wheel cylinder in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly.
5.9-8.8 N-m
1. Dust boot
2. Piston
Inspect for corrosion and damage
3. Piston cup
4. Spring and caps
23UOPX-02
5. Rubber cup and bleeder screw
6. Steel ball
7. Wheel cylinder body
Inspect for corrosion and damage
P-30

PARKING BRAKE SYSTEM
PARKING BRAKE SYSTEM
TROUBLESHOOTING GUIDE
Problem
Brakes do not
release
Parking brake does
not hold well Possible cause
Improper return of parking brake cable or improper ad-
justment
Excessive lever stroke
Brake cable stuck or damaged
Brake fluid or oil on pad or lining
Hardening of pad / lining surface or poor contact Remedy Repair or adjust
Adjust
Repair or replace
Clean or replace
Grind or replace Page P-32
P-31
P-32
P-i,28
ONOPX-080
PARKING BRAKE SHOE
Removal / Inspection / Installation
Disc brake
Removal and Installation (Refer to page P-23)
Inspection (Refer to page P-25)
Drum brake
Removal and Installation (Refer to page P-28)
Inspection (Refer to page P-29)
03u0Px-081
13UOPX-021
03UOPX-08
PARKING BRAKE (LEVER TYPE)
Inspection
Check that the stroke is within specification when the parking
brake lever is pulled with a force of 98 N (IO
kg, 22 lb).
Stroke: 5-7 notches
Adjustment
1. Before adjustment, start the engine and depress the brake
pedal several times while the vehicle is moving in reverse.
2. Stop the engine.
3. Remove the screw and the parking brake lever cover.
4. Remove the adjusting nut clip and turn the adjusting nut
at the front of the parking cable.
5. After adjustment, check the following points:
(1) Turn the ignition switch ON, pull the parking brake le
ver one notch, and check that the parking brake warn-
ing lamp illuminates.
(2) Verify that the rear brakes do not drag.
P-31

P PARKING BRAKE SYSTEM
PARKING BRAKE CABLE
Removal / Inspection / Installation
Caution
l Adjust the parking brake lever stroke.
l Depress the brake pedal a few times and check that the rear brakes do not drag while rotating
the wheels.
1. Remove the cable in the order shown in the figure.
2. Visually check each part, and replace it if necessary.
3. Install in the reverse order of removal.
16-23 (1.6-2.3, 12-17)
19-26 (1.9-2.6, 14-19)
N-m (m-kg, ft-lb)
03UOPX-08,
1. Rear console
3. Return spring 7. Clip
Removal / Installation
4. Front parking cable 8. Rear parking cable
. . . . . . . . . . . . . . . . . . . . . ..I. Section S 5. Nut (Disc brake type)
Inspect for damage and
2. Adjusting nut
6. Bolt (Drum brake type)
wear
P-32