Genuine Mazda Protege Brake Caliper

Mazda Protege Brake Caliper Parts and Q&A

• Caliper
  BPYH-26-99Z
  Q: How to properly disassemble and overhaul a brake caliper on Mazda Protege?

  A:

  Relax the front wheel lug nuts, lift the front of the car and rest it perfectly on the jackstands and then loosen the lug nuts and take off the wheel and make it ready to dismantle. Disassemble the brake hose of caliper by loosening the brake hose bolt and sealing the hose to avoid contamination and loss of fluid. Additionally, remove the W-shaped clip and the M-shaped spring out of the caliper; then remove pad pins, except that 1999 and later models do not have pad pins. Take out the lower caliper guide pin, lift the caliper and pads upwards to reach the pads and press the caliper piston inwards in case there are pads and shims attached. The next stage is to strip off the caliper mounting bolts and the caliper and two guide plates. In case of the overhaul, remove the bolt sleeves and boots, then the rubber cap and the bleeder screw. Take out caliper piston retaining ring and dust boot and place a piece of wood block or rags between the piston and caliper to avoid damage in extraction. Compressor Lift the piston out of the bore using compressed air and check the mating surfaces, and in case of scoring or rust on the mating surface, change the caliper unit. In case the components are in good state, take off the piston seal, clean all the components using brake system cleaner, and dry them. Install the correct rebuild kit by reassembling the caliper under the brake fluid right into the caliper bore with the seal and the piston sealed by dipping in the brake fluid. Install piston with a tight fit, and finally attach the new piston dust boot and retaining ring. Install the bleeder screw and rubber cap again, clean the bolt sleeves, and coated with high-temperature grease lightly, and put the sleeves and boots back. Check the brake disc to make sure that it can be reused and fit the caliper by reversing the steps taken to remove it, but using new copper sealing washers in the brake hose-to-caliperinterface. Lastly, bleed the brake circuit and ensure that there are no signs of leakages in the hose connections and test the brakes thoroughly before putting back the vehicle into normal service.
• Caliper
  GAZR-33-99ZA
  Q: What should you consider before overhauling brake calipers due to fluid leakage on Mazda Protege?

  A:

  On the event of an overhaul (which is normally due to leakage of the fluid) all options are to be explored, then proceed with the job. Replacement of a few new and factory rebuilt calipers can be done on exchange basis thus making it easier. Should you want to rebuild the calipers it is advisable to have a rebuild kit on hand before proceeding and to always have two calipers rebuilt at a time. Removal of the caliper is accomplished by first loosening the rear wheel lug nuts after which the rear of the car is elevated with jackstands and the wheel is then removed. Then remove the Parking Brake Cable off the caliper, and then remove the bolt of the brake hose and disconnect the brake hose inserting a plug to avoid contamination and loss of fluid. The rear disc manual adjustment gear screw plug must be removed, then the caliper piston of the brakes moved inward, by rotating the manual adjustment gear counterclockwise. Next, remove the lower caliper mounting bolt and the M shaped spring, however, 1999 and later models have spring clips in place. Slack the upper caliper mounting bolt and rotate the caliper away form the brake disc, and then remove the brake pads, shim plates, and caliper guide plates. Unscrew the upper mounting bolt then off the wheel hub, the caliper, the mounting support then the brake disc. Unplug the electrical connector of the speed sensor and strip off any required clips and bolts in case the vehicle is fitted with ABS. These models have complicated rear calipers, therefore; the calipers are not recommended to be overhauled and it is better to replace them as a pair with rebuilt units to have better service at lower cost. To install, the steps to be followed are the removal process in reverse order with the addition that the copper sealing washers be re-attached on brake hose-to-caliper connector. In case of presence of ABS, then install the ABS wheel sensor with due clearance between the sensor and toothed rotor. Lastly, be careful emptying the brakes circuit by checking that the hose connections are not leaking and also do a test before putting the vehicle back into normal service.