How to Change the Front Brakes on a 1996 Mazda 626

The Mazda 626 was first sold in the U.S. in 1979 in both coupe and sedan versions. The 626 lasted through 2002 after going through several generational changes. In 2003, the Mazda6 took the 626's place in the line-up. The front brakes on the 1996 version of the Mazda 626 are made of a semi-metallic material that does wear out over time. Replace the brake pads every 25,000 to 35,000 miles, based on driving habits. Replacing the front brake pads on the 1996 626 takes just a few hours.

Instructions

1

Open the vehicle's hood and remove the lid from the master cylinder fluid reservoir, the plastic container on the rear-driver's-side portion of the engine compartment. Remove half of the fluid from the reservoir, using a turkey baster. Transfer this fluid into a small, clean container to refill the reservoir, if needed.

2

Loosen the lug nuts from the front wheels, using the ratchet and socket. Raise the 626's front end, using the floor jack and support it with the jack stands. Remove the lug nuts and pull the front wheels from the vehicle.

3

Loosen and remove the caliper bolts, located on the rear of the brake caliper, with the ratchet and socket. Pull the caliper up and off the brake rotor (the metal disc). Support the caliper by attaching it to any suspension component near the caliper with the bungee strap.

4

Grab the brake rotor and pull it from the vehicle. A light tapping with the rubber mallet will free the rotor, if it is not easily pulled off.

5

Close the jaws of the micrometer and press the "Reset" or "Zero" button the calibrate it. Open the jaws of the micrometer, place them over the disc portion of the rotor and close the jaws, make note of the measurement.

6

Turn the rotor 45 degrees and repeat step 5 until you are at the original measuring point. If the rotor's thickness is less than .870 inches at any point, it must be replaced. If the rotor's thickness is above this specification place the rotor back on the hub it was removed from, or have it resurfaced by a professional then place it back on the hub.

7

Grab the brake pads and remove them from the caliper. Take note of the position the pads are in, as the new pads must be placed in the same fashion.

8

Place the C-clamp over the caliper, position it so the fixed portion is contacting the rear of the caliper and the screw portion is contacting the caliper's piston, the cylindrical object inside the caliper.

9

Place the new brake pads into the caliper in the same position the old ones were in. Place the caliper over the brake rotor and tighten the caliper bolts to 22 to 29 foot-pounds of torque.

10

Repeat steps 3 through 9 for the brakes on the other side of the vehicle.

11

Place the wheels back on the 626 and hand-tighten the lug nuts.

12

Remove the jack stands from under the vehicle and lower it to the ground.

13

Tighten the lug nuts, in a crossing-pattern, to 85 foot-pounds using the torque wrench and a socket.

14

Check the fluid level in the master cylinder reservoir. Add fluid from the small container if the level is not between the "Min" and "Max" lines on the reservoir. If the fluid is not needed, discard of it properly as it may become contaminated if left in an unapproved container for extended periods of time. Many auto parts stores will take old fluids, free of charge, for disposal. Close the 626's hood.

15

Press and release the brake pedal until it feels firm. This presses the caliper piston out and against the new brake pads.