1997 MAZDA MX-5 lock

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, 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, check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (B2300, B3000 & B4000)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder reservoir. Raise and support vehicle. Remove front wheel assemblies. Place a
large "C" clamp on caliper.
2. Tighten clamp to bottom piston in cylinder bore. Remove clamp. Remove 2 caliper pin bolts. Remove
caliper from rotor and wire aside. Slide brake pads off caliper anchor plate. Remove anchor plate (if
necessary). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING
SPECIFICATIONS (FRONT) .
3. To install, reverse removal procedure. Use "C" clamp and old pad to push caliper piston into piston bore
until piston bottoms out. Bleed air from brake system (if necessary).
Removal & Installation (Miata, Millenia, MPV, MX-6, 626 & 929)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt.
See Fig. 4
, Fig. 5 or Fig. 6 . Pivot caliper upward and support using rope.
2. Remove pads, shims, guide plates or pad guides and "V" springs (if equipped). Replace pad if lining
thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT)
.
3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push
piston full
y inward to install disc pads.
(38-46)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 10 © 2005 Mitchell Repair Information Company, LLC.

openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS. Remove remaining mounting
bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system.
FRONT BRAKE ROTOR
Removal & Installation (B2300, B3000 & B4000 2WD)
1. Raise and support vehicle. Remove front wheel assemblies and brake caliper. See FRONT DISC
BRAKE PADS . Remove grease cap, cotter pin, retainer, adjusting 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 17-25 ft. lbs. (23-34 N.m) to seat bearings. Back off adjusting nut 1/2 turn. Tighten adjusting nut to
18-20 INCH lbs. (2.0-2.3 N.m). Install bearing retainer and NEW cotter pin. DO NOT turn adjusting nut
to align cotter pin.
Removal (B2300, B3000 & B4000 4WD With Automatic Locking Hubs)
1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE
PADS . Remove retainer washers from lug nut studs. Remove automatic locking hub assembly from
spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 9
. Carefully pull cam
assembly off wheel bearing adjusting nut. If necessary, rotate adjusting nut slightly to relieve pressure on
locking key.
3. Using a magnet, remove locking key. Using 2 3/8" Hex Lock Nut Wrench (49-UN01-037), remove wheel
bearing adjusting nut. Remove outer wheel bearing and 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. 7
. After assembly is complete, wheel to
spindle end play should be .000-.003" (.00-.08 mm).
CAUTION: Extreme caution must be used when aligning adjusting nut lug with
spindle locking key slot to prevent damage to locking key.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Removing Front Rotor (B2300, B3000 & B4000 With Automatic Locking Hubs)
Courtesy of FORD MOTOR CO.
Removal (B2300, B3000 & B4000 4WD With Manual Locking Hubs)
1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE
PADS . Remove retainer washers from lug nut studs. Remove manual locking hub assembly from
spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 10
. Using Lock Nut Wrench
(49-UN01-042), remove outer wheel bearing lock nut. Remove lock washer. Using lock nut wrench,
remove inner wheel bearing lock nut. Remove outer wheel bearing, cup and rotor.
Installation
When installing rotor, outer bearing and inner lock nut, tighten inner lock nut to 35 ft. lbs. (47 N.m) to seat
bearings. Spin rotor, and back off inner lock nut 1/4 turn. Tighten inner lock nut to 16 INCH lbs. (1.8 N.m). To
install remaining components, reverse removal procedure. See Fig. 10
. After assembly is complete, wheel to
spindle end pla
y should be .000-.003" (.00-.08 mm).

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 17 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Removing Front Rotor (B2300, B3000 & B4000 With Manual Locking Hubs)
Courtesy of FORD MOTOR CO.
Removal & Installation (Except B2300, B3000 & B4000)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with
brake hose connected. See FRONT DISC BRAKE CALIPER
. Wire caliper aside. Remove rotor-to-hub
screws (if equipped). 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
. To install, reverse removal
procedure.
REAR DISC BRAKE PADS
Removal & Installation (Miata & Protege)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove manual adjustment gear
concealment plug from caliper. See Fig. 11
. Insert an appropriate size Allen wrench through hole and
turn manual adjustment gear counterclockwise to retract caliper piston.
2. Remove lower guide bolt from caliper. Rotate caliper upward and wire side. 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. Turn manual adjustment gear clockwise until brake pads slightly touch
rotor. Turn manual ad
justment gear back 1/3 turn.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 18 © 2005 Mitchell Repair Information Company, LLC.

2. To install, reverse removal procedure. Use Disc Brake Expander (49-022 1-600C) and an old pad to push
piston fully inward to install disc pads.
Fig. 12: Exploded View Of Rear Disc Brake Assembly (MPV & 929)

Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-3)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove upper caliper mounting bolt.
See Fig. 13
. Rotate caliper downward. Remove "V" spring, brake pads, shims and guide plates. Replace
brake pads if pad lining thickness is less than .04" (1.0 mm).
2. To install, reverse removal procedure. Using Brake Piston Wrench (49 FA18 602), turn wrench clockwise
until piston bottoms out in brake caliper.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 20 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Exploded View Of Rear Disc Brake Assembly (MX-3)
Courtesy of MAZDA MOTORS CORP.
Removal & Installation (MX-6 & 626)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect
parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See
Fig. 11
. Insert an appropriate size Allen wrench through hole and turn manual adjustment gear
counterclockwise to retract caliper piston.
2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove "M"
springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04" (1.0 mm).
3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly
touch rotor. Turn manual ad
justment gear back 1/3 turn.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Removal & Installation (RX7)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove lower guide bolt from caliper.
Rotate caliper upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates.
Replace pad if lining thickness is less than .04" (1.0 mm).
2. To install, reverse removal procedure. Use Disc Brake Piston Wrench (49-FA18-602) to rotate piston
clockwise to install disc pads. Ensure grooves in piston are aligned. See Fig. 14
.
Fig. 14: Aligning Brake Caliper Piston (RX7)

Courtesy of MAZDA MOTORS CORP.
REAR BRAKE CALIPER
Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 626 & 929)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. On all models except MPV and 929,
release parking brake and disconnect parking brake cable from caliper. On all models, disconnect brake
hose from caliper.
2. On Miata, MX-6, Protege and 626, remove manual adjustment gear concealment plug from caliper. See
Fig. 11
. Insert an appropriate size Allen wrench through hole and turn manual adjustment gear
counterclockwise to retract caliper piston.
3. On all models, remove guide bolts from caliper. Remove brake caliper from caliper mount. To install,
reverse removal procedure. Bleed air from system.
Removal & Installation (Millenia)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 22 © 2005 Mitchell Repair Information Company, LLC.

caliper. Remove rear brake pads. See REAR DISC BRAKE PADS. Remove remaining caliper guide
bolt. Remove brake caliper from caliper mount. To install, reverse removal procedure. Bleed air from
system.
Removal & Installation (MX-3)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect
parking brake cable from caliper. Disconnect brake flexhose from caliper. See Fig. 13
.
2. Remove upper caliper mounting bolt. Rotate caliper downward. Remove "V" spring, pads, shims and
guide plates. Replace brake pads if pad lining thickness is less than .04" (1.0 mm).
3. Remove lower caliper mounting bolt. Pull caliper toward center of vehicle to slide it off of caliper mount.
To install, reverse removal procedure. Using Brake Piston Wrench (49 FA18 602), turn wrench clockwise
until piston bottoms out in brake caliper. Bleed air from system.
REAR BRAKE ROTOR
Removal & Installation (Miata, Millenia, MPV, MX-3, MX-6, Protege, RX7, 626 & 929)
1. Raise and support vehicle. Remove rear wheel assemblies. Remove rear brake caliper with brake hose
connected. See REAR BRAKE CALIPER
. Support caliper using wire. Remove rotor-to-hub screws (if
equipped). 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
.
3. To install, reverse removal procedure. Check end play at grease cap. On 929, if end play
exceeds .004" (.10 mm), check lock nut torque or replace wheel bearings. On all other models, if end play
exceeds .002" (.05 mm), check lock nut torque or replace wheel bearings.
REAR BRAKE SHOES & WHEEL CYLINDERS
Removal (B2300, B3000 & B4000)
1. Raise and support vehicle. Remove rear wheel assemblies. Remove brake drum. Machine or replace drum
as necessary if inner diameter is not as specified. See DRUM BRAKE SPECIFICATIONS
.
2. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage adjusting lever from adjusting
screw by pulling backwards on self adjuster cable. See Fig. 15
.
3. Move outboard side of adjusting screw upward and back off pivot nut as far as possible. Pull adjusting
lever, cable and adjusting lever spring down and toward rear to unhook pivot hook from large hole in
secondary shoe. DO NOT pry pivot hook from hole.
4. Remove adjusting lever spring and adjusting lever. Remove secondary shoe-to-retracting spring. Remove
primary shoe-to-retracting spring. Unhook cable anchor and remove anchor pin plate.
5. Note color and position of shoe hold-down springs for reassembly. Remove cable guide, shoe hold-down
springs, brake shoes, adjusting screw, pivot nut and socket. Remove parking brake link spring and link.
6. Disconnect parking brake cable from lever. Remove secondary shoe. Disassemble parking brake lever
from shoe by removing retaining clip and spring washer. See Fig. 16
. Remove brake cylinder-to-shoe
connectin
g links. Disconnect brake line from brake cylinder. Remove brake cylinder.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:03 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.