Mazda RX-8 BRAKE DISC INSPECTION

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Warning
•  Do not use the vehicle-equipped jack to jack up the vehicle for brake disc inspection. The jack may slip during servicing and cause an accident. Always use a lift or a garage jack to jack up the vehicle and use a rigid rack when performing brake disc inspection.
Caution
•  Do not operate the brake pedal with the caliper removed. The caliper may be damaged if the brake pedal is operated with the caliper removed.
•  Do not operate the parking brake lever with the rear caliper removed. The rear caliper may be damaged if the parking brake lever is operated with the rear caliper removed.

Required tools

•  Micrometer
•  Torque wrench
•  Handle
•  Socket (12 mm, 14 mm, 21 mm)

Front Brake Disc Inspection

1.  Remove the front tire.

2.  Remove the brake hose installation bolt from the upper arm and disconnect the brake hose.

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3.  Remove the caliper installation bolt on the underside of the vehicle.

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4.  Move the caliper in the direction shown by the arrow and remove it from the mounting support.

5.  Hang the removed caliper in a place out of the way using a cable.

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6.  Remove the disc pad from the mounting support.

7.  Clean the brake disc surface where it contacts the pad using brake cleaner.

8.  Measure the thickness of the brake disc using a micrometer.

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•  If the brake disc thickness is the usable minimum or less, the brake disc has to be replaced with a new one. Consult a Mazda Dealer for replacement.
Brake disc usable minimum thickness
22 mm {0.87 in}
Standard brake disc thickness (New part)
24 mm {0.94 in}

9.  Install the disc pad to the mounting support.

10.  Move the caliper in the direction shown by the arrow and remove it from the mounting support while being careful not to distort the brake hose.

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11.  Tighten the caliper installation bolt to the specified torque.

Tightening torque
22―31 N·m {2.3—3.1 kgf·m, 17—22 ft·lbf}

12.  Install the brake hose to the upper arm and tighten the brake hose installation bolt to the specified torque.

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Tightening torque
19―25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

13.  Install the front tire and tighten the nuts to the specified torque.

Tightening torque
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

14.  After installation, pump the brake pedal a few times and verify that the brakes do not drag.


Rear brake disc inspection

1.  Remove the rear tire.

2.  Remove the caliper installation bolts and remove the caliper from the mounting support.

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3.  Hang the removed caliper in a place out of the way using a cable.

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4.  Remove the disc pad from the mounting support.

5.  Clean the brake disc surface where it contacts the pad using brake cleaner.

6.  Measure the thickness of the brake disc using a micrometer.

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•  If the brake disc thickness is the usable minimum or less, the brake disc has to be replaced with a new one. Consult a Mazda Dealer for replacement.
Brake disc usable minimum thickness
16 mm {0.63 in}
Standard brake disc thickness (New part)
18 mm {0.71 in}

7.  Install the disc pad to the mounting support.

8.  Install the caliper to the mounting support with the brake hose not twisted, and tighten the caliper installation bolts to the specified torque.

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Tightening torque
22―31 N·m {2.3—3.1 kgf·m, 17—22 ft·lbf}

9.  Install the rear tire and tighten the nuts to the specified torque.

Tightening torque
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}

10.  After installation, pump the brake pedal a few times and inspect the following:

•  Parking brake lever stroke
•  Brake drag