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Mazda 3 Service Manual: Front Brake (Disc) Inspection

Mazda 3 Service Manual / Brakes / Disc Brakes / Front Brake (Disc) Inspection

Brake Judder Repair Hints

Description

1. Brake judder concern has the following 3 characteristics:

Steering wheel vibration

1. The steering wheel vibrates in the rotation direction. This characteristic is most noticeable when applying brakes at a vehicle speed of 100140 km/h {62.286.9 mph}

.

Floor vibration

1. When applying the brakes, the vehicle body shakes back and forth. The seriousness of the shaking is not influenced by vehicle speed.

Brake pedal vibration

1. When applying the brakes, a pulsating force tries to push the brake pad back. The pulsation is transmitted to the brake pedal.

2. The following are the main possible causes of brake judder:

Due to an excessive runout (side-to-side wobble) of the disc plate, the thickness of the disc plate is uneven.

1. If the runout is more than 0.05 mm {0.002 in}

at the position 10 mm {0.39 in}

from the disc plate edge, uneven wear occurs on the disc plate because the pad contacts the plate unevenly.

2. If the runout is less than 0.05 mm {0.002 in}

, uneven wear does not occur.

The disc plate is deformed by heat.

1. Repeated panic braking may raise the temperature in some portions of the disc plate by approx. 1,000 C {1,832 F}

. This results in a deformed disc plate.

Due to corrosion, the thickness and friction coefficient of the disc plate change.

1. If the vehicle is parked in damp conditions for a long time, corrosion occurs on the friction surface of the disc plate.

2. The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction coefficient and causes a reaction force.

Inspection and repair procedure


Lateral runout inspection

1. To secure the disc plate and the hub, insert the washer (thickness 10 mm {0.39 in}

, inner diameter more than 12 mm {0.47 in}

) between each hub bolt and the hub nut, then tighten all the hub nuts.

NOTE:

2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of the disc plate 10 mm {0.39 in}

from the disc plate edge.


3. Rotate the disc plate one time and measure the runout.

Thickness variation inspection

1. Clean the disc plate-to-pad friction surface using a brake cleaner.

2. Measure the points indicated in the illustration using a caliper (micrometer).


3. Subtract the minimum value from the maximum, and if the result is not within the specification, machine the disc plate using a lathe.

WARNING:

Disc Plate Thickness Inspection

CAUTION:

1. Measure the thickness of the disc plate.

Disc Pad Thickness Inspection

1. Jack up the front of the vehicle and support it with safety stands.

2. Remove the wheels and tires.

3. Verify the remaining thickness of the pads.

4. Replace the pads as a set (right and left wheels) if either one is at or less than the minimum thickness.


Caliper (Rear) Disassembly/Assembly
1. Disassemble in the order indicated in the table. 1 Dust seal (See Dust Seal Assembly Note.) 2 Bleeder cap 3 ...

Front Brake (Disc) Removal/Installation [Mzr 2.0, Skyactiv G 2.0, Mzr 2.5]
1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, pump the brake pedal a few times and verify that the brakes do not drag. ...

Other materials:

Steering Shaft Inspection
1. Inspect the column bearing for excessive play and damage. 2. Verify that the measurement of the steering shaft indicated in the figure is as specified. If not within the specification replace the steering shaft component. Steering shaft length 315320 mm {12.4112.59 ...

Check Valve Inspection [Skyactiv G 2.0]
Airflow Inspection 1. Remove the vacuum hose.. 2. Blow air into the vacuum hose using your mouth from the vacuum pump side and verify that the air flows to the intake manifold side, then blow air from the intake manifold side and verify that the air does not flow to the vacuum pump side. ...

Vehicle Speed Sensor (VSS) Inspection [FS5 A EL]
On-Vehicle Inspection 1. Inspect the power supply circuit for the VSS. a. Remove the insulator from the transaxle. b. Disconnect the VSS connector. c. Switch the ignition to ON (engine off). d. Measure the voltage at VSS connector terminal A (harness-side). If there is a ...

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