1994 MAZDA MX-5 Workshop Manual

BRAKE SYSTEM Removal I Installation note Brake pipe Caution ,..- Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off im- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas" 2. Disconnect/connect the brake pipes by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13-22 N-m (1 3-2.2 kgf-m, 9.4-1 6 ftslbf) Gartner Banana

BRAKE SYSTEM P FRONT BRAKE (DISC) Quick Inspection, On-vehicle Disc pad 1. On level ground, jack up the front of the vehicle and sup- port it with safety stands. 2. Remove the wheels. 3. Sight through the caliper inspection hole and verify the remaining thickness of the pad. Thickness: 1 .Omm (0.04 in) min. I I 05UOPX-034 Replacement (Disc pad) 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. 1. Lock bolt 3. Outer shim Removal Note ................... below 4. Inner shim 2. Disc pad 5. Guide plate Installation Note ............. page P-26 Removal note Lock bolt 1. Remove the lower lock bolt. 2. Rotate the caliper upward and support it with a piece of rope. Gartner Banana

P BRAKE SYSTEM Installation note Disc pad 1. Push the piston inward by using the 2. Install the new pads in the mounting SST. support. 1 I 15UOPX-030 Removal I lnstallation (Caliper) 1. On level ground, jack up the front of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure. 3. Install in the reverse order of removal. 4. Tighten all nuts and bolts to the specified torques, referring to the figure. 1. Brake hose 5. Shim 2. Connecting bolt 6. Bolt 3. Caliper 7. Mounting support Disassembly / Inspection / 8. Disc plate Assembly .................. page P-28 Inspection ................... page P-27 4. Disc pad ................... Inspection page P-27 Gartner Banana

BRAKE SYSTEM P Inspection Check the following and repair or replace parts as neces- sary. Disc pad 1. Oil or grease on facing. 2. Abnormal wear or cracks. 3. Deterioration or damage by heat. 4. Remaining lining thickness. Thickness Standard: 8.0mm (0.31 in) Minimum: 1 .Omm (0.04 in) Disc plate Tighten the disc plate to the wheel hub by using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface. 1. Runout. Runout: O.lmm (0.004 in) max. 2. Wear and damage. Thickness Standard: 20.0mm (0.79 in) Minimum: 18.0mm (0.71 in) Gartner Banana

P BRAKE SYSTEM CALIPER Disassembly I Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal. REPLACE 1. Dust seal 3. Piston seal Inspect for damage and poor sealing Disassembly Note ................ below 2. Piston 4. Bleeder screw and bleeder cap Disassembly Note ................ below 5. Caliper body Inspect for wear and rust Inspect for damage and cracks Disassembly note Piston 1. Place a piece of wood in the caliper. 2. Gently blow compressed air through the hole to force the piston out of the caliper. 9MUOPX-075 Piston seal Remove the piston seal by using the SST. Gartner Banana

BRAKE SYSTEM ,$, .... "P ...% REAR BRAKE (DISC) Quick Inspection, On-vehicle Disc pad 1. On level ground, jack up the rear of the vehicle and sup- port it with safety stands. 2. Remove the wheels. 3. Sight through the caliper inspection hole and verify the remaining thickness of the pad. Thickness: 1 .Omm (0.04 in} min. I I 05UOPX-043 Replacement (Disc pad) 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. 1. Plug 4. M-spring 2. Manual adjustment gear 5. Disc pad Removal Note ................... below Inspection ................... page P-31 Installation Note ............. page P-30 6. Shim 3. Lock bolt 7. Guide plate RETRACTING BRAKE PADS Removal note Manual adjustment gear Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston back. Gartner Banana

BRAKE SYSTEM ADJUSTING BRAKE PADS Installation note Manual adjustment gear 1. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate. -1 2. Return the manual adjustment gear counterclockwise 113 turn. Removal 1 lnstallation (Caliper) 1. On level ground, jack up the rear of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Inspect all parts and repair or replace as necessary. 5. Tighten all nuts and bolts to the specified torques, referring to the figure. Parking brake cable Removal I Inspection 1 Installation ................. page P-36 Connecting bolt Brake hose Plug Manual adjustment gear Removal Note ............... page P-29 Installation Note ................. above Lock bolt 7. Caliper Disassembly I Inspection 1 Assembly .................. page P-32 8. Disc pad Replacement ................ page P-29 Inspection ................... page P-31 9. Bolt 10. Mounting support 11. Disc plate Inspection ................... page P-31 Gartner Banana

BRAKE SYSTEM P Inspection Check the following and repair or replace parts as neces- sary. Disc pad 1. Oil or grease on facing. 2. Abnormal wear or cracks. 3. Deterioration or damage by heat. 4. Remaining lining thickness. Specified thickness : 8.0mm (0.31 in) Minimum : l.Omm (0.04 in) Disc plate Tighten the disc plate to the wheel hub by using two wheel nuts. When measuring runout, measure at the outer edge of the disc plate surface. 1. Runout. Runout: O.lmm (0.004 in) max. 2. Wear or damage. Thickness Standard: 9.0mm (0.35 in) Minimum: 8.0mm (0.31 in) Gartner Banana