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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 100—140 km/h {62.2—86.9 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:

Expansion Valve Removal/Installation
1. Disconnect the negative battery cable.. 2. Discharge the refrigerant from the system.. CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing ...

Starter Cut Relay Inspection [MTX]
Advanced Keyless Entry And Push Button Start System Only 1. Disconnect the negative battery cable. 2. Remove the following parts: a. Front scuff plate (LH). b. Front side trim (LH). c. Side wall. d. Console. 3. Set the bonnet release lever out of the way.. 4. Remove the lower panel.. ...

Back Up Light Switch Removal/Installation [C66 M R]
1. Remove the battery cover.. 2. Disconnect the negative battery cable.. 3. Remove the aerodynamic under cover No.2.. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 1 Back-up light switch connector 2 ...

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