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Mazda RX7. Manual - part 19

BRAKE SYSTEM

Article Text (p. 2)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:54PM

wheel turns freely. Repeat procedure for opposite side. Adjust the
parking brake. Install plugs in the adjusting holes.

BRAKE PEDAL HEIGHT ADJUSTMENT

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Application In. (mm)

GLC Wagon
Man. Trans. .................................... 7.5-7.7 (190-195)
Auto. Trans. ................................... 7.7-7.9 (195-200)
RX7 .............................................. 7.5-7.7 (190-195)
B2000 & B2200 .................................... 8.1-8.3 (205-210)

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PARKING BRAKE

1) With service brakes properly adjusted, raise and support
the rear of the vehicle. Remove parking brake lever boot or console,
if necessary. Release the brake lever. Turn the adjusting screw or
nut to obtain specified clearance. On Pickups, turn adjusting nut at
equalizer under the vehicle.
2) The lever should be pulled with a force of 22 lbs. to
obtain a stroke of 3-7 notches on GLC Wagon, 5-9 notches on GLC, 6-8
notches on RX7, 7-9 notches on 626, and 5-10 notches on Pickups.
3) Reinstall brake lever boot or console. Remove supports
and lower vehicle. On all models, operate parking brake several times
and make sure rear wheels rotate freely.

NOTE: Insure that the rear brakes are not dragging and the parking
brake warning light is activated when the lever is pulled 1
notch.

BRAKE WARNING LIGHT

All Models (If Equipped)
1) Light indicates parking brake is engaged and also warns
of low fluid level. With engine running, light should glow when
parking brake lever is pulled 1 notch and go off when lever is fully
released.
2) To check warning light operation with engine running,
release parking brake lever and ensure light is off. Raise master
cylinder reservoir cap and light should glow. If not, check switch
and wire connector.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal
1) Raise and support the front of the vehicle. Remove the
wheels. Detach brake hose attachment from shock absorber, if
necessary.

BRAKE SYSTEM

Article Text (p. 3)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:54PM

2) On RX7 remove lower caliper guide pin and
pivot caliper body up out of way. On GLC Wagon and Pickups remove
locking clips and stopper plates.
3) Remove caliper body and hang from frame with wire. Do not
disconnect hydraulic lines. On all models, remove anti-rattle springs
(clips), pads, and shims, if equipped.

Installation
1) To install, reverse removal procedure. Before mounting
caliper, loosen bleed screw, and seat piston. Tighten bleed screw.
2) After pad installation, depress brake pedal several times
to seat pads. Bleed hydraulic system, if required.

NOTE: Grease pad mounting support, caliper contact area, and shims
with special grease (NLGI No. 2 or equivalent).

REAR DISC BRAKE PADS

Removal (RX7)
1) Raise and support the rear of the vehicle. Remove wheel.
Disconnect parking brake cable from caliper. Remove lower caliper
attaching bolt.
2) Lift the lower side of caliper. Remove anti-rattle
spring. Remove disc brake pads and shims.

Installation
1) Using brake piston wrench (49 FA18 602), turn piston
clockwise until piston is inserted into caliper fully.
2) Position piston so that dowel on pad will seat in piston
stopper groove. To complete installation, reverse removal procedure.

FRONT DISC BRAKE CALIPER

Removal
1) Raise and support the front of the vehicle. Remove the
wheel. Disconnect and plug the fluid line at caliper. On RX7, remove
lower caliper bolt, lift the caliper body, and remove by sliding
toward the inside of the vehicle.
2) On GLC Wagon and Pickups, remove locking clips, stopper
plates, and anti-rattle spring. Lift off caliper. Remove disc pads as
previously described.

Installation
To install, reverse removal procedure and bleed hydraulic
system.

REAR BRAKE CALIPER

Removal (RX7)
1) Raise and support the rear of the vehicle. Remove the
wheel. Disconnect parking brake cable from caliper.
2) Remove caliper attaching bolt (lower side). Lift up

BRAKE SYSTEM

Article Text (p. 4)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:54PM

caliper. Slide the caliper toward the inside of the vehicle and
remove the caliper. Disconnect the brake hose from the caliper.

Installation
To install caliper, reverse removal procedure and bleed
hydraulic system.

FRONT DISC BRAKE ROTOR

Removal (All Models)
1) With caliper assembly removed, remove wheel hub grease
cap, cotter pin, lock plate and ring adjusting lock nut.
2) Remove thrust washer and outer bearing from hub. Slide
hub and rotor assembly from spindle. On Pickups, place wheel in a
soft-jawed vise, make mating marks, remove hub-to-rotor bolts, and
separate rotor from hub.

Installation
To install, reverse removal procedure, and tighten
hub-to-rotor bolts evenly. Adjust wheel bearings. See Wheel Bearing
Adjustment in SUSPENSION section.

REAR BRAKE DRUM

Removal (All Models)
Raise and support the rear of the vehicle. Release parking
brake. Remove the wheel. On Pickups, remove brake drum retaining
screws and insert into tapped holes of brake drum. Turn screws evenly
and force brake drum off flange.

Installation (All Models)
To install, reverse removal procedure. Tighten retaining
screws evenly (if equipped). On GLC & 626, adjust wheel bearings. See
Wheel Bearing Adjustment in SUSPENSION section.

Fig. 2: Exploded View of GLC Wagon Rear Brakes
Other models are similar.

BRAKE SYSTEM

Article Text (p. 5)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:54PM

REAR BRAKE SHOES

Removal (All Models)
1) With brake drum removed, remove brake shoe return
springs, retaining springs and guide pins. Remove brake shoes.
2) Remove parking brake strut and disconnect parking brake
cable from operating lever of secondary shoe.

Installation
1) Lubricate adjusting screw threads and contact surfaces of
shoes and backing plate with brake grease. Install parking brake
operating lever to secondary shoe and secure with clip. Engage
operating lever with parking brake cable.
2) Position operating strut between slots of shoes. Mount
assembly to backing plate so slots in shoes are toward adjusting
screws. Install return springs and retainer springs.

MASTER CYLINDER

Removal
1) Disconnect fluid level sensor coupler, if equipped.
Disconnect and plug hydraulic lines at master cylinder to prevent
entry of dirt and loss of fluid.
2) Remove nuts attaching master cylinder to firewall or
power brake unit and remove master cylinder from vehicle. On RX7,
remove proportioning valve by-pass bolt.

Installation
To install, reverse removal procedure and bleed hydraulic
system.

POWER BRAKE UNIT

Removal
1) Remove master cylinder from power brake unit before
removing power brake unit. Disconnect vacuum line at power brake unit.
2) From inside vehicle, remove cotter pin and clevis pin
attaching push rod to brake pedal, and separate.
3) Remove nuts retaining power unit to firewall. Remove
power brake unit and master cylinder as an assembly. Separate master
cylinder from power brake unit.

Installation
To install, reverse removal procedure and bleed hydraulic
system.

OVERHAUL

FRONT DISC BRAKE CALIPER

Disassembly
1) Thoroughly clean exterior of caliper and remove retainer

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