1995 lincoln mark viii service manual

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1995-1999 Buick Riviera Steering Vibration/Shudder/Moan During Parking Maneuvers on Dry Pavement (Install Power Steering Pressure (Inlet) and/or Return (Outlet) Hose Assembly)

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Filed Under (Buick Manuals) by admin on 11-02-2012

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1. Verify that the power steering pump reservoir is full. 2. Verify that the accessory drive belt is in good condition and that the pulleys are not bent or damaged. 3. Verify proper belt tension and operation of the belt tensioner. 4. Check for power steering hose ground out conditions. 5. Check for good engine idle and correct engine RPM. 6. Check to see that the rear transaxle mount does not have a plastic assembly aid installed which is used Subject: Steering Vibration/Shudder/Moan During Parking Maneuvers on Dry Pavement (Install Power Steering Pressure (Inlet) and/or Return (Outlet) Hose Assembly) Models: 1995-99 Buick Riviera 1997-2001 Buick Park Avenue, Ultra 2000-2001 Buick LeSabre 2000-2001 Pontiac Bonneville • 1995-98 Buick Riviera • 1997-98 Buick Park Avenue and Ultra • 1999 Buick Riviera • 1999-2001 Buick Park Avenue and Ultra • 2000-2001 Buick LeSabre • 2000-2001 Pontiac Bonneville • If fluid level is low, fill and check for leaks. • If power steering system has air in the system, perform the “Bleeding Air from Power Steering System” procedure as described in the Power Steering System sub-section of the Service Manual. Important: When performing the “Bleeding Air from Power Steering System” procedure, it is important that the front of the vehicle is supported by the lower control arms. If the vehicle is not supported by the lower control arms, the procedure may cause the strut bushing to dislocate and cause new concern. for assembly purposes. If the assembly aid is installed, remove the assembly aid and install the rear transaxle mount. 7. With the vehicle on dry pavement, maneuver the vehicle in parking positions. If the steering vibrates/shudders or moans in this test, replace the power steering pressure hose and/or the harmonic balancer. Important: A defective harmonic balancer on the 1995 Buick Riviera can influence steering vibrations after power steering hose installation. Important: When installing the pressure hose on the 1995 Buick Riviera, pull down on the pressure hose at the rear of the engine or bend the hose to allow clearance between the hose and the front of the dash. Power Steering Pressure (Inlet) Hose Replacement Procedure For 1995-1998 Vehicles: 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting and Jacking in the General Information section of the Service Manual. 2. Drain the power steering fluid. Refer to Draining the Power Steering System in the Power Steering section of the Service Manual. 3. Remove the power steering gear assembly heat shield (1). 4. Disconnect the power steering pressure hose from the power steering pump assembly (4). 5. Remove the bolt/screws from the retaining clips (3). 6. Disconnect the power steering pressure hose from the power steering gear assembly (2). 7. Remove the power steering pressure hose assembly from the vehicle. 8. Install the power steering pressure hose assembly to the vehicle. 9. Connect the power steering pressure hose to the power steering pump assembly (4). 10. Connect the power steering pressure hose to the power steering gear assembly (2). Tighten Tighten the power steering pressure hose to the steering gear to 27 N·m (20 lb ft). 11. Install the bolt/screws to the retaining clips (3). Tighten Tighten the retaining clip bolt/screws to 6 N·m (53 lb in). 12. Install the power steering gear assembly heat shield (1). 13. Lower the vehicle. 14. Fill and bleed the power steering system using, J 43485. Refer to Corporate Bulletin Number 83-32-09, dated November, 1998. Power Steering Pressure (Inlet) and Return (Outlet) Hose Replacement Procedure For 1999-2001 Vehicles: 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting and Jacking in the General Information section of the Service Manual. 2. Drain the power steering fluid. Refer to Draining the Power Steering System in the Power Steering section of the Service Manual. 3. Remove the LH front wheel/tire assembly. 4. Remove the LH lower splash shield. 5. Remove the lower radiator air deflector (engine splash shield, if installed.

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1995 Nissan-Datsun 200SX Timing Chain/ Front Cover Revised Procedure

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Filed Under (Nissan Manuals) by admin on 27-01-2012

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Removal 1. Set # 1 piston at TDC on its compression stroke. 2. Remove the spark plug wires. 3. Remove the rocker cover (see Figure 1). 4. Remove the coolant reservoir tank with bracket and reposition it for clearance. 5. Support the engine with a suitable jack. 6. Remove cylinder head front mounting bracket. 7. Remove engine front mounting, then the engine front mounting bracket. 8. Remove cylinder head front cover 9. Remove the upper chain tensioner (see Figure 2). 10. Wipe off the links of the upper timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket (see Figure 3) 11. Remove the four (4) front cover to cylinder head bolts. 12. Remove side and lower engine compartment splash covers. 13. Remove the accessory drive belts. 14. Remove the crankshaft pulley. 15. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock (Refer to MA section of the Service Manual). 16. Drain engine oil. 17. Remove intake manifold support of engine front side. 18. Remove power steering pump, pump bracket and tension rod. Position pump aside for clearance. 19. Remove the thermostat housing (See Figure 4) 20. Remove the lower chain tensioner (see Figure 5). 21. Remove the front exhaust tube. Refer to the “FE” section (Exhaust System) of the Service Manual. 22. Remove the front and rear engine gussets (if equipped) on either side of the oil pan. NOTE: On A/T models, remove the rear plate cover. 23. Remove the oil pan (see Figure 6). a. Insert the Tool between the cylinder block and oil pan. CAUTION: Be careful not to damage the aluminum mating face. Do not insert a screwdriver, or the oil pan flange will become damaged. b. Slide the Tool by tapping it on the side of the Tool with a hammer. 24. Remove the A/C compressor and position it aside for clearance. 25. Remove the A/C and alternator bracket with the alternator. 26. Remove the oil pump drive spacer. CAUTION: Be careful not to scratch the drive spacer when removing it. 27. Remove the front cover bolts and front cover. CAUTION: One bolt is located on the water pump (see Figure 7). *1: Located on engine front mounting bracket. *2: Located on the water pump. *3: Located on the power steering oil pump adjusting bar. CAUTION: Be careful not to tear or damage the cylinder head gasket. 28. Remove the cylinder block to front cover alignment dowels. CAUTION: Do not hit the dowels or the cylinder block will crack. 29. Wipe off the links of the lower timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the idler sprocket and crankshaft sprocket (see Figure 8). Installation 1. Install the crankshaft sprocket, making sure the mating marks face the front of the engine. 2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION:

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ALL INFINITI BRAKE NOISE/ JUDDER/ PEDAL FEEL DIAGNOSIS AND REPAIR MANUAL

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Filed Under (Infiniti Manuals) by admin on 23-04-2012

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SERVICE PROCEDURE 1. Verify the condition by road testing the vehicle with the customer. 2. Determine the specific brake issue based on the description in the Service Information above. 3. Follow the appropriate repair procedure(s), listed on the following pages, for your specific issue BRAKE NOISE • Brakes can make a range of noises when applied or released. Some noises are normal and no repair action should be taken. • Use the following descriptions to identify the specific type of brake noise and the appropriate repair: Squeak noise when the brakes are cold: • Usually occurs during the first few stops in the morning. • This is a normal condition. No service action is necessary Squeak noise with the brakes at normal operating temperatures: • listed under Brake Service on page 5 of this bulletin and the appropriate Service Manual procedures. • Refer to technical bulletins specific to the model of vehicle regarding this issue. If there are no bulletins for the car you are working on, install OE type pads using the information Notes about brake pads and brake noise: Original Equipment (OE) brake pads are installed on all current Infiniti vehicles at the factory. The OE pads use a Non-asbesto • s Organic (NAO) compound. The NAO material provides state of the art resistance to squeal noise. • ervice parts and must be used if replacing brake pads under the terms of • ted under Brake Service on page 5 of this bulletin and the appropriate Service Manual Gro n s after coming to a stop: • It is a normal condition. No repair or service is necessary. Groan noise during stopping: • Usually caused by glazing of the rotor’s surface as a result of heavy or frequent braking. • Refer to technical bulletins specific to the model of vehicle regarding this issue. • Replace the brake pads, then resurface the rotors and finish them with sand paper. Refer to Brake Service on page 5 for additional detail. Single clunk noise from front suspension when applying the brakes: • The noise is a result of the brake pads shifting in the direction of rotor rotation when the brakes are applied. Can be duplicated by lightly touching the brake pedal. • • If the brake pedal is pushed hard, the noise is less likely to occur. Make sure the brake pads and pad hardware (shims, springs, clips, etc) are installed correctly. Refer to ASIST for vehicle specific brake service information. Refer to Brake Service on page 5 for additional detail. Mull e he engine is started: • st er models, the self check occurs the first aches 5 mph after the engine is started. ors or drums. • WARNING: Brake dust may be hazardous if inhaled. Refer to the Service Manual (ESM) for brake • n and lubrication of brake pads, CAUTION: Do not get grease on the brake pad friction surface. A • Brake Judder is caused by rotor thickness variation and/or rotor run out.

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Acura MDX Torque Converter Shudder or Vibration Between 35 and 40 MPH Repair Manual

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Filed Under (Acura Manuals) by admin on 24-11-2011

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1. To confirm the client’s complaint, test-drive the vehicle on a smooth road, preferably with a slight incline. Set the cruise control between 35 and 40 mph, and monitor the engine rpm using the vehicle’s tachometer, or use the HDS to take a snapshot of the engine rpm. 2. If the engine speed fluctuates several hundred rpm while maintaining a constant vehicle speed, disconnect the EGR valve and retest the vehicle. •If the fluctuation is gone, refer to the EGR troubleshooting in the service manual. •If the engine rpm still fluctuates, and the transmission does not have any other symptoms (shifting problems, slipping, transmission DTCs) go to step 3. 3. Drain the transmission fluid, then strain it through a paint strainer. •If you find little or no contamination in the strainer, the ATF is OK, even if it smells burnt, is discolored, and/or the magnetic drain plug has small chips, flakes, or metal fuzz on it. Go to REPAIR PROCEDURE A . •If you find large amounts of contamination (pieces of metal or friction material) in the strainer, go to REPAIR PROCEDURE B . REPAIR PROCEDURE A 1. Remove the torque converter: •Refer to page 14-203 of the 2003-04 MDX Service Manual , or •Online, enter keyword A/T REM , and select A/T Removal from the list. 2. Install the torque converter: •Refer to page 14-215 of the 2003-04 MDX Service Manual , or •Online, enter keyword A/T INSTALL , and select A/T Installation from the list. 3. Update the PGM-FI software using HDS version 1.018.016 or later (see SOFTWARE INFORMATION ). Refer to service bulletin 01-026, Updating the ECM/PCM . 4. Do the idle learn procedure: •Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. •Start the engine, and let it run until it reaches its normal operating temperature (cooling fan cycles twice). •Let the engine idle with the throttle fully closed for 10 minutes. REPAIR PROCEDURE B Follow the IN-WARRANTY EXCHANGE steps in service bulletin 90-009, Automatic Transmission In- Warranty Exchange Program , to order a remanufactured A/T, replace the failed A/T, and return the failed A/T core. 1. Remove the transmission: •Refer to page 14-203 of the 2003-04 MDX Service Manual , or •Online, enter keyword A/T REM , and select A/T Removal from the list. 2. Clean the transmission cooler. Refer to service bulletin 89-015, ATF Cooler Cleaner . 3. Install a remanufactured transmission: •Refer to page 14-215 of the 2003-04 MDX Service Manual , or •Online, enter keyword A/T INSTALL , and select A/T Installation from the list. 4. Update the PGM-FI software using HDS version 1.018.016 or later (see SOFTWARE INFORMATION ). Refer to service bulletin 01-026, Updating the ECM/PCM . 5. Do the idle learn procedure: •Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are turned off. •Start the engine and let it run until it reaches its normal operating temperature (cooling fan cycles twice). •Let the engine idle with the throttle fully closed for 10 minutes

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1995-1997 FORD EXPLORER TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP

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Filed Under (Ford Manuals) by admin on 20-01-2012

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TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP ISSUE to the Data Link Connector (DLC) underneath The diagnostic procedure for binding or shudder the steering wheel. Monitor for any Diagnostic from transfer case in slow, tight turns while in 4 Trouble Codes (DTCs) set by the transfer case Auto mode may be inaccurate for some vehicles. that could indicate incorrect speed sensor function. Codes could include, but are not ACTION limited to: Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure. •P1836 – Front propshaft sensor circuit failure •P1837 – Rear propshaft sensor circuit failure DIAGNOSTIC PROCEDURE •P1874 – Hall effect sensor power short circuit to battery 1997 EXPLORER •P1875 – Hall effect sensor power circuit 1. Test drive the vehicle in 4 Auto, 4 High and 4 failure Low. Evaluate the vehicle in each of these NOTE modes. The vehicle should bind in turns in both ADDITIONAL CODES COULD BE SET AS WELL. 4 High and 4 Low, but not in 4 Auto. The 4 PLEASE REFER TO THE APPROPRIATE YEAR High mode is intended for severe winter EXPLORER SERVICE MANUAL FOR COMPLETE weather or off-road driving only. It is not LISTING AND EXPLANATION. intended for use on dry or merely wet pavement. 3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and 2. Verify the instrument panel has the proper 4X4 replace accordingly. Drive the vehicle to verify if selection label (Figure 1). Proceed to 1995-97 the shudder/binding has been eliminated. Send Explorer heading, Step 1. replaced speed sensor to the Ford Warranty 1995-97 EXPLORER Parts Return Center, Canton, MI. NOTE 4. Using NGS Tester, monitor the Parameter 4 AUTO IS THE FAR LEFT SWITCH POSITION Identification Display (PID) on the transfer case ON 1997 MODELS AND IS THE MIDDLE clutch duty cycle. If the 4 Auto mode reads POSITION ON 1996 MODELS. something higher than one (1), verify speed sensors have not set any Generic Electronic 1. If during test driving, the vehicle shudders or Module (GEM) DTCs and follow the speed binds in 4 Auto during slow forward or reverse sensor diagnostic procedure in the above Step parking lot maneuvers, proceed to Step 2. 2. Verify the following while checking PID: Mode Duty Cycle Indicator 4 Auto 0 or 1 4 High 13 4 Low 38 at 5 MPH 5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil

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INFINITI BRAKE NOISE/ JUDDER/ PEDAL FEEL DIAGNOSIS AND REPAIR MANUAL

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Filed Under (Infiniti Manuals) by admin on 06-02-2012

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APPLIED VEHICLES: All Infiniti SERVICE INFORMATION • This bulletin is to assist you in responding to customer questions about brake operation, and provides diagnostic and repair information for each item listed, if any should occur. • Most brake issues fall into the following categories: a. Brake Noise: A squeak, squeal, clunk, or groan that occurs when the brakes are applied or released. b. Brake Judder: A vibration that can be felt in the vehicle, steering wheel, or brake pedal when the brakes are applied. c. Pedal Feel: The effort needed to operate the brakes is too high or too low. SERVICE PROCEDURE 1. Verify the condition by road testing the vehicle with the customer. 2. Determine the specific brake issue based on the description in the Service Information above. 3. Follow the appropriate repair procedure(s), listed on the following pages, for your specific issue. BRAKE NOISE • Brakes can make a range of noises when applied or released. Some noises are normal and no repair action should be taken. • Use the following descriptions to identify the specific type of brake noise and the appropriate repair: Squeak noise when the brakes are cold: • Usually occurs during the first few stops in the morning. • This is a normal condition. No service action is necessary Squeak noise with the brakes at normal operating temperatures: • listed under Brake Service on page 5 of this bulletin and the appropriate Service Manual procedures. • Refer to technical bulletins specific to the model of vehicle regarding this issue. If there are no bulletins for the car you are working on, install OE type pads using the information Notes about brake pads and brake noise: Original Equipment (OE) brake pads are installed on all current Infiniti vehicles at the factory. The OE pads use a Non-asbesto • s Organic (NAO) compound. The NAO material provides state of the art resistance to squeal noise. • ervice parts and must be used if replacing brake pads under the terms of • ted under Brake Service on page 5 of this bulletin and the appropriate Service Manual Gro n s after coming to a stop: • It is a normal condition. No repair or service is necessary. These pads are available as s the Infiniti new car warranty. Loud continuous squeak/squeal noise: • Occurs with or without braking. • This is a normal brake function. It occurs when the brake pad wear indicators contact the rotor. It indicates the brake pads are worn out and need to be replaced. Install new brake pads using the information lis procedures. anoise when slightly releasing the brake • This is sometimes called “creep groan

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Honda Clunk or Squeak From Rear Suspension Repair Manual

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Filed Under (Honda Manuals) by admin on 15-02-2012

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REPAIR PROCEDURE NOTE: ISIS online service manual information is only available for vehicles 1990 and newer. 1. Remove the rear trailing arm: •Refer to the suspension section of the appropriate service manual, or •Online, enter keyword REAR SUSPENSION, then select Suspension Arms Replacement from the list. 2. Mark the trailing arm at the arrow on the bottom of the bushing 3. Place the arm on a hydraulic press, supported by the hub base, with the spindle facing up. 4. With the hub driver, press the old bushing out of the trailing arm. 5. Install the new bushing with the short end toward the outside of the vehicle. Align the arrow with the mark you made on the trailing arm. 6. Press the new bushing into the trailing arm until its edge is 10 to 12 mm above the surface of the arm. 7. Reinstall the trailing arm. 8. If necessary, repeat steps 1 thru 7 to install a new bushing in the other rear trailing arm. 9. Bleed the brake system: •Refer to the brakes section of the appropriate service manual, or •Online, enter keyword BLEED, then select Brake System Bleeding from the list. 10. Check the wheel alignment, and adjust it if needed: •Refer to the suspension section of the appropriate service manual, or •Online, enter keyword WHEEL ALIGNMENT, then select Wheel Alignment – Rear Toe Inspection/Adjustment from the list

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2004-2005 FORD F-150 FRONT BRAKE ROUGHNESS/ SHUDDER WHILE BRAKING REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 10-06-2012

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ISSUE b. If new level (47 fin) rotors are present, Some 2004/2005 F-150 vehicles built before perform one (1) of the following: 11/29/2004 may exhibit front brake roughness and or shudder while braking. (1) If rotors are within minimum thickness specifications, machine the rotors using ACTION the Rotunda on vehicle brake lathe and Service the rack and pinion, rotors, and caliper the Rotunda adapter kit 201-R0093. assemblies as needed, based on vehicle build date Refer to the Workshop Manual, Section and current part levels installed on the vehicle. 206-00 for the correct on-vehicle brake Refer to the following Service Procedure. lathe procedure. SERVICE PROCEDURE (2) If rotors are beyond machinable thickness, the front rotors must be 1. Vehicles built prior to 8/20/2003 require the replaced. replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop 3. Install new service fix calipers. Manual, Section 206-03 and 211-02. NOTE 2. Determine if the vehicle has the old or new REPLACE CALIPERS WITH NEW SERVICE FIX level rotors (Figure 1). CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. PART NUMBER PART NAME 6L3Z-2B120-A Caliper Asy (Right Side) 6L3Z-2B121-A Caliper Asy (Left Side) 5L3Z-1102-AB Rotor (4X2, 6 Lug) 5L3Z-1102-BA Rotor (4X2, 7 Lug) 5L3Z-1125-AA Rotor (4X4, 6 Lug) 5L3Z-1125-BA Rotor (4X4, 7 Lug) 6L3Z-3504-AA Steering Gear (Super Cab/Crew 4X2) 6L3Z-3504-BA Steering Gear (Super Cab/Crew 4X4) Figure 1 – Article 05-21-19 6L3Z-3504-CA Steering Gear (Regular Cab 4X2) 6L3Z-3504-DA Steering Gear (Regular Cab 4X4) a. If old level rotors, replace the front rotors 6L3Z-3C294-AA Retainer Spindle Nut and front caliper assemblies. Refer to Workshop Manual, Section 206-00 for front rotor and caliper replacement.

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1995 Toyota 4Runner STARTING AND CHARGING SYSTEMS REPAIR MANUAL

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Filed Under (Toyota Manuals) by admin on 15-03-2012

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TROUBLE SHOOTING NOTE: See TROUBLE SHOOTING – BASIC PROCEDURES article in GENERAL INFORMATION. 1) If a no-start condition exists and battery is known to be good, connect test light or voltmeter between starter solenoid terminal No. 50 and ground. See Figs. 6 and 7. 2) Turn ignition switch to START position. If test light or voltmeter does not indicate voltage, check main fusible links and large ampere main fuses in engine compartment relay box. If fusible links and fuses are okay, see IGNITION SWITCH CONTINUITY TEST and/or STARTER RELAY TEST under ON-VEHICLE TESTING. ON-VEHICLE TESTING NOTE: Before testing, ensure battery is fully charged, battery cables and terminal ends are tight and clean, and engine grounds are secure. CLUTCH START SWITCH TEST 1) Switch is located above clutch pedal on bracket. Disconnect wiring harness connector from switch. 2) Connect ohmmeter probes to switch terminals. Depress clutch pedal. If continuity does not exist, adjust or replace clutch start switch. If continuity exists, check circuit to starter relay for open, and check starter relay. See STARTER RELAY TEST. CLUTCH START CANCEL SWITCH TEST 1) Locate switch in left dash panel. Remove right lower instrument panel to access switch connector. Disconnect wiring harness connector from switch pigtail connector. See Fig. 1. 2) Connect negative lead of ohmmeter to terminal No. 1. Ensure continuity does not exist between connector terminals No. 1 and 2, terminals No. 1 and 3, and terminals No. 2 and 3. Check operation of switch by connecting jumper wires from 12-volt battery. Connect positive lead to terminal No. 3 and negative battery lead to terminal No. 1. 3) Using ohmmeter, ensure continuity does not exist between connector terminals No. 1 and 2 until switch button is pushed. When switch button is pushed, switch light should come on and continuity should exist. Disconnect battery and ensure continuity does not exit between terminals No. 1 and 2. If switch does not test as specified, replace switch. Fig. 1: Identifying Clutch Start Cancel Switch Connector Terminals Courtesy of Toyota Motor Sales, U.S.A., Inc. IGNITION SWITCH CONTINUITY TEST WARNING: Deactivate air bag system before performing any service operation. For 1996 4Runner, see AIR BAG RESTRAINT SYSTEM article. 1995 1) Disconnect negative battery cable. Removedriver’s lower instrument panel cover. Remove upper and lower steering column covers if needed. Locate ignition switch wiring harness 8-pin connector. See Figs. 2-3. 2) With ignition switch in LOCK position, there should be no continuity between any terminals. With ignition switch in ACC position, there should be continuity between terminals No. 2 and 3. With ignition switch in ON position, there should be continuity between terminals No. 1, 2 and 3, and between terminals No. 7 and 8. 3) With ignition switch in START position, there should be continuity between terminals No. 1, 4 and 6, and between terminals No. 7 and 8. If continuity is not as specified, replace switch.

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1995 Mazda MX-6 FRONT DISC BRAKE PADS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mazda Manuals) by admin on 16-02-2012

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REMOVAL & INSTALLATION FRONT DISC BRAKE PADS Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . 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) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Fig. 2: Exploded View Of Front Brake Disc Assembly Courtesy of MAZDA MOTORS CORP. MINIMUM PAD LINING SPECIFICATIONS (FRONT) Application Thickness In. (mm) MX-6, 626 FRONT DISC BRAKE CALIPER Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all 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 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 table. To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation 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. 3 . 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 adjustment gear back 1/3 turn.

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