Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMAZDA1999626 ES, 2.5 D, STANDARDREPAIR AND DIAGNOSISBRAKESANTI-LOCK BRAKES/TRACTION CONTROL (2)ADJUSTMENTSMASTER CYLINDER PUSH ROD
1999 Mazda 626 ES, 2.5 D, Standard
Master Cylinder Push Rod
1999 Mazda 626 ES, 2.5 D, StandardSECTION Master Cylinder Push Rod
- Before installing master cylinder, measure clearance between master cylinder piston and power brake unit push rod. Place Adjusting Gauge (49-B043-001 ) on power brake unit.
- Using a hand-held vacuum pump, apply 19.7 in. Hg to power brake unit. Turn adjusting gauge nut counterclockwise until gauge rod just contacts push rod end of power brake unit. Perform STEP 1 in illustration. See Fig 1 .
- Lightly push on end of adjusting gauge rod to ensure it is properly seated. Verify no gap exists between adjusting nut and adjusting gauge body. Remove adjusting gauge from power brake unit without disturbing adjusting nut. Place adjusting gauge on master cylinder as seen in STEP 2 in illustration. See Fig 1
.NOTE: When lightly pushing on end of adjusting gauge rod in step 4 , only use enough pressure to bottom rod in piston. Too much pressure may cause piston to move inward and give a false reading.
- Lightly push on end of adjusting gauge rod to ensure gauge rod is bottomed in master cylinder piston. Ensure no clearance exists between adjusting gauge body and adjusting nut (clearance "B") or between adjusting gauge body and master cylinder (clearance "C"). Perform STEP 2 in illustration. See Fig 1 .
- If clearance "B" exists, push rod is too short. If clearance "C" exists, push rod is too long. To adjust clearance "B", go to next step. To adjust clearance "C", go to step 8
.NOTE: Push rod threads are specially designed so bolt becomes harder to turn past a certain point to prevent loosening of bolt. Turn bolt only within this range.
- To adjust clearance "B", lightly push on end of adjusting gauge rod. Using a feeler gauge, measure clearance between adjusting nut and adjusting gauge. Perform STEP 3 in illustration. See Fig 1 .
- Using Push Rod Adjuster (49-B043-004) and Adapter (49-B043-003), turn push rod nut to lengthen power brake booster push rod an amount equal to amount measured at clearance "B" in step 6 . Perform STEP 4 in illustration. See Fig 1 .
- To adjust clearance "C", measure and record adjusting gauge rod height D1. Perform STEP 5 in illustration. See Fig 1 . Turn adjusting nut until adjusting gauge body sits squarely on master cylinder.
- Turn adjusting nut only enough for body to touch adjusting gauge. Measure and record adjusting gauge height D2 of adjusting gauge rod. Perform STEP 6 in illustration. See Fig 1 . Subtract D1 from D2 measurement.
- Using push rod adjuster and adapter, turn push rod nut to shorten power brake booster push rod an amount equal to difference between height D1 and D2. Perform STEP 4 in illustration. See Fig 1 .
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.