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Disassembly & Reassembly

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2004 Mazda B4000, 2004 Mazda B3000, 2004 Mazda B2300, 2003 Mazda B4000, and 2003 Mazda B3000. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the front disc brake caliper. See FRONT DISC BRAKE PADS  under REMOVAL & INSTALLATION. Drain remaining brake fluid from the front disc brake caliper. Secure caliper in a vise.
  2. Place a block of wood between the caliper bridge and the caliper pistons. See Fig 1 . Apply low air pressure to the fluid port in the disc brake caliper. Force out the caliper pistons to the block of wood. Remove the block of wood and the caliper pistons.
  3. Remove and discard the piston seals and boots. See Fig 2 . Inspect calipers for damage, corrosion or excessive scoring. If the caliper bores are excessively scored or corroded, replace the front disc brake caliper.
  4. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with appropriate brake fluid. Install the piston seal. Install the piston boot. Be careful not to damage or dislodge the piston seal.
  5. Insert the caliper piston. Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. Install the caliper. See FRONT DISC BRAKE PADS  under REMOVAL & INSTALLATION.
Fig 1: Removing Caliper Pistons
G00281123Courtesy of MAZDA MOTORS CORP.
Fig 2: Exploded View Of Disc Brake Caliper
G00281124Courtesy of MAZDA MOTORS CORP.
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