1994 MAZDA MX-5 brakes

OUTLINE OUTLINE SPECIFICATIONS Item TY ~e Specifications Suspended Pedal level ratio Maximum stroke mm (in) 4.1 : I 1 20 14.72) - -- TY ~e Bore mm (in) Pad dimensions (area x thickness) mm2 x mm {in2 x in) Tandem (with level sensor) 22.22 (0.875) -- - TY ~e Cylinder bore mm (in) Disc plate dimension (effective diame- ter x thickness) mm {in) Disc (ventilated) 51.1 (2.01) Pad dimensions (area x thickness) mm2 x mm (in2 x in) Cylinder bore mm {in) Disc plate dimensions (effective diameter x thickness) mm (in) Disc (solid) 31.75 (1.25) Size mm {in) Vacuum multiplier 21 4 (8) Proportioning bypass valve (PBV) FMVSS 11 6: DOT-3 Brake fluid Mechanical, two rear brakes Hand lever Parking brake TY Pe - Operation system Gartner Banana

BRAKE SYSTEM TROUBLESHOOTING GUIDE Problem Poor braking Brakes pull to one side Brakes do not release Pedal goes too far (Too much pedal stroke) Abnormal noise or vibra- tion durlng braking Possible cause Leakage of brake fluid Air in lines Worn pad Brake fluid, grease, oil, or water on pad Hardening of pad surface or poor contact Malfunction of disc brake piston Malfunction of master cylinder Malfunction of power brake unit Malfunction of check valve (vacuum hose) Damaged vacuum hose Deterioration of flexible hose Malfunction of proportioning bypass valve (PBV) Worn pad Brake fluid, grease, oil, or water on pad Hardening of pad surface or poor contact Abnormal wear, distortion, or eccentricity of disc Malfunction of automatic adjuster in rear brake Looseness or deformation of dust cover mounting bolt Malfunction of disc brake piston Worn or improperly adjusted wheel bearing preload lmproper adjustment of wheel alignment Unequal tire air pressure No brake pedal play lmproper adjustment of push rod clearance Clogged master cylinder return port Pad not returning properly lmproper return of malfunction of brake caliper piston Excessive runout of disc plate lmproper adjustment of wheel bearing preload Air in system because of insufficient brake fluid lmproper adjustment of pedal play Worn pad Air in lines Worn pad Deterioration of pads Brakes do not release Foreign material or scratches on disc plate contact surface Looseness of caliper mounting bolt(s) Damage or deviation of disc contact surface Poor contact of pads Insufficient grease on sliding parts Action Repair Air bleed Replace Clean or replace Grind or replace Replace Repair or replace Repair or replace Repair or replace Replace Replace Replace Replace Clean or replace Grind or replace Repair or replace Repair Tighten or replace Repair or replace Replace or adjust Adjust Adjust Adjust Adjust Clean Repair Replace Replace Adjust or replace Add fluid and bleed air Adjust Replace Bleed air Replace Grind or replace Repair Clean Tighten Replace Repair or replace Apply grease Page - P- 7 P-25,29 P-25,29 P-25,29 P-28,32 P-11, 14 P-22 P-22 P-22 P- 7 P-23,24 P-25,29 P-25,29 P-25,29 section M - section M P-28,32 section M section R section Q P- 9 P-l2,15 - - P-28,32 section M section M P- 7 P- 9 P-25,29 P- 7 P-25,29 P-25,29 - - P-26,30 section M P-25,29 - 15UOPX-00 Gartner Banana

BRAKE SYSTEM P MIRROR AIR BLEEDING The brakes should be bleed whenever a brake line is dis- connected. If a hydraulic line is disconnected at the mas- ter cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the next closest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next farthest slave cylinder until all four cylinders have been bled. 1. On level ground jack up the vehicle and support it evenly on safety stands. 2. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 3. Place the other end of the vinyl tube in a clear container. 4. One person should depress the brake pedal a few times, and then hold it in the depressed position. 5. A second person should loosen the bleeder screw, drain out the fluid, and close the screw by using the SST. 6. Repeat steps 4 and 5 until only clean fluid is seen. The reservoir should be kept about 3/4 full during bleeding to prevent air from reentering the lines. 7. Modify the brake pipe tightening torque to allow for a torque wrench-SST combination. (Refer to section GI) "Torque Formulas". 8. Tighten the brake pipe by using SST. 9. Check for correct brake operation. 10. Verify that there is no fluid leakage. Clean away any spilled fluid with rags. 11. After bleeding the air, add brake fluid to the reservoir up to the specified level. BRAKE HYDRAULIC LINE On-vehicle Inspection Check the following and replace parts as necessary. 1. Cracks, damage, and corrosion of the brake hose 2. Damage to the brake hose threads 3. Scars, cracks, and swelling of the flexible hose 4. All lines for fluid leakage Gartner Banana

BRAKE SYSTEM P MASTER CYLINDER (STANDARD) Removal / Installation 1 lnspection 1. Remove in the order shown in the figure, referring to Removal Note. ,, 2. Install in the reverse order of removal, referring to Installation Note. 3. After installation, add brake fluid, bleed the brakes, and check for fluid leakaae. 1. Fluid level sensor connector 5. Proportioning bypass valve and bracket Inspection ................... page P-13 6. Master cylinder 2. Brake pipe Installation Note ............. page P-12 Removal Note ............... page P-12 Disassembly 1 Assembly I 3. Connector bolt Inspection ................. page P-18 4. Nut and washer Gartner Banana

BRAKE SYSTEM P MASTER CUUNDER PRESSURE kPa #gflcm2, psi) 15UOPX-025 Replacement PROPORTIONING BYPASS VALVE Inspection When disconnecting and connecting the brake pipes, do so by using the flare nut wrench SST. 1. Connect the SST and the adapters to the brake pipes as shown in the figure. 2. Bleed the air from the brake system. (Refer to page P-7.) 3. Measure the fluid pressure from the master cylinder and to the rear brakes. If not as specified, replace the valve assembly. Specification 4. Add brake fluid and bleed the air. (Refer to page P-7.) 5. Check the brake lines for fluid leakage. Fluid pressure kPa (kgf/cm2, psi) Caution Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off immediately. A A' I B 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to lnstallation Note. 3. After installation: (1) Add brake fluid and bleed the air. (Refer to page P-7.) (2) Check the brake lines for fluid leakage. 6' 1. Brake pipe 2. Bolt Removal Note ............... page P-24 3. Proportioning bypass valve Installation Note ............. page P-24 Gartner Banana

P PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM TROUBLESHOOTING GUIDE I Problem I Possible cause I Brake fluid or oil on pads -- Brakes do not release Parking brake does not hold well I Hardening of pad surfaces or poor contact Improper return of parking brake cable or improper adjustment Excessive lever stroke Brake cable stuck or damaged Action 1 page 1 d Repair or adjust Adjust Repair or replace Clean or replace Grind or replace 25UOPX-026 PARKING BRAKE LEVER Inspection 1. Depress the brake pedal several times. 2. Verify that the stroke is within specification when the parking brake lever is pulled with a force of 196 N (20 kgf, 44 Ibf). Stroke: 7-9 notches Adjustment 1. On level ground, jack up the rear of the vehicle until the wheels are free to turn, and support it with stands. 2. Depress the brake pedal several times. 3. Remove the cover. 4. Turn the adjusting nut to adjust the lever stroke. --/, 5. Depress the parking brake pedal one notch, and verify that the parking brake warning light comes on. Release the parking brake. 6. Turn the wheels by hand, and verify that the brakes do not drag. 7. Lower the vehicle. Gartner Banana

PARKING BRAKE SYSTEM PARKING BRAKE CABLE Removal / Inspection 1 Installation 1. Block the wheels firmly. 2. Release the parking brake. 3. Remove the parking brake lever. 4. On level ground, jack up the vehicle and support it evenly on safety stands. 5. Remove the parking brake cable in the order shown in the figure. 6. Install in the reverse order of removal. 7. After installation: (1) Adjust the parking brake lever stroke. (Refer to page P-34.) (21 Deoress the brake oedal a few times. (3j ve;ify that the rear brakes do not drag while the wheels are rotated by hand. 1. Adjusting nut and clip 2. Clip 3. Spring lnspect for weakness 4. Front cable lnspect for damage 5. Rear cable lnspect for damage Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ANTILOCK BRAKE SYSTEM (ABS) DESCRIPTION - 1. There is the following distinctive characteristics in the ABS vehicles compared with the non-ABS vehicles. Note that it does not indicate malfunction. When the brakes are applied rapidly or on a slippery road surface, the ABS will activate; the brake pedal will pulsate slightly and the vehicle and the steering wheel will vibrate slightly. When the vehicle speed reaches approximately 6 kmh (3.8 mph}, the pump motor sound is heard momentarily. This sound is due to ABS self-diagnosis. 2. By retaining or reducing the hydraulic fluid pressure in the hydraulic unit, the ABS tester is used to locate the cause of a problem within the antilock brake system. Because there is no way to check the ABS control unit itself, replace the control unit assembly only after first confirming that the other electrical parts operate normally. PREPARATION SST Wrench, flare nut 49 H026 101 A Installer, sensor rotor 49 F027 007 Attachment 072 For removal and installation of brake pipe For installation of sensor rotor (rear) For removal of sensor rotor (front) 49 0839 425C Puller set, bearing Installer, oil seal Harness, adapter For removal of sensor rotor (front) For installation of sensor rotor (front) For connection of ABS tester Gartner Banana