Brakes

Contents
Are there any brake upgrade kits?
How do I do a rear drum brake to disc brake conversion?
Are there any master cylinder upgrades available?
My manual recommends DOT 3 brake fluid, is it safe to use DOT 4 or 5?
Is there a special "break-in" procedure when I upgrade my brakes?


Are there any brake upgrade kits?
    There is a very limited selection of possible brake upgrades for a Protegé
    currently. Upgrade kits available are usually too cost prohibitive for
    practical street use. Goodridge makes stainless steel brake lines for all
    models. Another option for 3rd generations and Mazda3's that have rear
    disc brakes are stainless steel brake lines from AutoExe. MazdaSpeed used
    to make stainless steel brake lines for the 1st and 2nd generations also.
    The part numbers are:
    1st generation (w/rear disc only): 9N2D-43-991
    2nd generation (w/rear disc only): 9DD5-43-991

     For 1st generations:
     Brembo brakes are available, as well as KVRs.

     Cross drilled and slotted rotors are also available.
     MazdaSpeed brake pads are also available:
       QBM5-49-280 front brake pad set for 1.6L and B8 1.8L (doesn't incl. shims)
       QGF1-49-280 front competition brake pad set for 1.6 and B8 1.8L (no shims)
       QDG5-49-280 front brake pad set for BP 1.8L (does not include shims)
       QSR5-49-480A rear brake pad set (does not include shims)
       QVH5-49-480 rear pad set for GT-R/GT-Ae (doesn't incl. shims FDY1-26-49Z)
       QCD5-49-480 rear B-Spec. brake pad set for GT-R/GT-Ae (doesn't incl. shims)

    For 2nd generations:

     KVR cross drilled rotors are available for front and rear, as well as
     carbon pads. MazdaSpeed also has brake pads:
       QDG5-49-280 front brake pad set for 1.8L
       QBM5-49-280 front brake pad set for Z5 1.5L (does not include shims)
       QEP5-49-480B rear brake pad set (does not include shims)
       QEP6-49-480 rear B-Spec. brake pad set (does not include shims)

    For 3rd generations:

     KVR drilled or slotted rotors and carbon pads are available. Lug
     configuration is unknown. For models with rear drum brakes, the
     front brakes can be upgraded from the tiny 9.3" rotors to beefier 10.2"
     ones from a 99-00 ES or 01-03 DX/LX. Calipers and other parts will have
      to be swapped also. Porterfield also has carbon Kevlar brake pads. Their
     "R4S" model is street able. 2001+ 4 wheel disc brake cars can upgrade to the
     European spec brakes offered in the MazdaSpeed Protege. AutoExe also make
     "street" and "sport" brake pads for all 3rd generation Protegé's (cars with the
     larger European brakes use the GW Capella Wagon 4WD front and 2WD rear
     parts) as well as slotted rotors. MazdaSpeed also has brake pads meant for the
     Capella (JDM 626) but are compatible with some Proteg
é brake setups. The
     part numbers are:
       QWC5-49-280 front brake pad set (does not include shims GAYR-33-29ZA)
         for: all 1.8L, all 2.0L w/rear disc (exc. MSP & Euro 323F 2.0 Sport),
               2002-2003 2.0L w/rear drums
       QVH5-49-480 rear pad set (does not include shims FDY1-26-49Z)
         for MazdaSpeed
Protegé, MazdaSpeed Familia, Euro rear discs, 4WD models
       QCD5-49-480 rear B-Spec. brake pad set (doesn't incl. shims, meant for RX-7)
         for MazdaSpeed Protegé, MazdaSpeed Familia, Euro rear discs, 4WD models
       QFD1-49-480 rear R-Spec. brake pad set (doesn't incl. shims, meant for RX-7)
         for MazdaSpeed Protegé, MazdaSpeed Familia, Euro rear discs, 4WD models

     Front brakes can be upgraded to larger calipers and pads on the 1.6L models as
     Here are the parts needed for the upgrade:
       GAZR-33-98Z front right caliper
       GAZR-33-99Z front left caliper
       BLYM-33-23Z front brake pad set [North America/Asia]
       CBY9-33-23Z front brake pad set [Oceania]
     For 1999-2000 models:
       GE4T-43-800 brake booster
       The following are for non-ABS equiped cars:
         BJ0S-43-40Z master cylinder
         B26K-43-900 proportioning valve
       The following are for ABS equiped cars:
         BJ0P-43-40Z master cylinder
         C100-43-853 distribution block
    
For 2001-2003 models:
       BL8M-43-800 brake booster
       The following are for non-ABS equiped cars:
         BJ4T-43-40Z master cylinder
         B26K-43-900 proportioning valve
       The following are for ABS equiped cars:
         BJ3K-43-40Z master cylinder
         C100-43-853 distribution block
  
  If your car can benefit from this upgrade, then chances are, your rear brakes are
     the drum type. You can choose to
upgrade your rear brakes to discs also.
     If you live outside of North America, you can choose to purchase the calipers
     with brake pads preinstalled. The total cost of purchasing the caliper and pads
     separately maybe more or the same, so it maybe an advantage to you. These part
     numbers may not be available in your market.
       GG5D-33-980C front right caliper (includes pads) [Asia]
       GG5D-33-990C front left caliper (includes pads) [Asia]
       CB80-33-980C front right caliper (includes pads) [Europe/Oceania]
       CB80-33-990C front left caliper (includes pads) [Europe/Oceania]
  
     The European spec brake upgrade is a direct bolt on to the 4 wheel disc
     brake cars. Here are the parts needed for the upgrade:
       GFYY-26-251 rear disc rotor
       BPYH-26-98Z rear right caliper
       BPYH-26-99Z rear left caliper
       GGYB-26-43Z rear brake pad set
       GF3Y-33-25XA front disc rotor
       BPYH-33-98Z front right caliper
       BPYH-33-99Z front left caliper
       CBY3-33-23Z front brake pad set
       BL4G-43-800 brake booster (optional)
     These parts are readily available at any US/Canada dealership. The brake
     calipers are specially painted silver for the MazdaSpeed Protegé thus they
     are very expensive. A much cheaper solution is to import the unpainted ones.
     Here are the cheaper, unpainted calipers (they use
     the same rotors and brake pads as the list above):
       GFYP-26-98ZA rear right caliper
       GFYP-26-99ZA rear left caliper
       GFYP-33-98Z front right caliper
       GFYP-33-99Z front left caliper
     Special caution when installing these brakes: the brake pads are high
     friction metallic pads and will require a very clean rotor and pad surface
     prior to installation. Be sure to clean the rotor and air dry them thoroughly
     before installing them with clean hands per Mazda's recommendations.

     If you don't mind doing a little bit of fabrication, the huge 320mm (front) /
     314mm (rear) MazdaSpeed6 brakes will also fit. The parking brake cables
     will also need to be changed out and slightly modified in order for them to fit.
     These parts are very expensive new, so finding them used is your best bet!
     However, if you insist on new parts:
       G31Y-26-251 rear brake rotor (need 2)
       GPYB-26-43Z rear brake pad set
       GPZB-26-98ZA rear right caliper (with bracket)
       GPZB-26-99ZA rear left caliper (with bracket)
       G31Y-33-25XA front brake rotor (need 2)
       GPYA-33-23ZG front brake pad set
       GPYA-33-28XC front caliper bracket (need 2)
       GPYA-33-61XA front right caliper
       GPYA-33-71XA front left caliper
       BP4K-33-233 front caliper bracket spring (need 2)
       GA2B-44-375B parking brake cable (need 2; requires fitment modifications)

    For Mazda3's
     Owners who have the 2.0L engine cars outside of Europe can upgrade to the
     larger 300mm front and 280mm rear brake setup used on the 2.3L, 2.5L and
     European 2.0L Mazda3's (versus 278mm front and 265mm rear). Owners of
     engines other than the 2.0L and 2.3L in the rest of the world can also benefit
     from this same upgrade. The following parts are needed (you need 2 of each):
       BPYS-33-28XC front caliper mounting bracket (for 1st generations)
       C256-33-281 front caliper mounting bracket (for 2nd generations)
       C26Y-33-25XC front rotor
       BPYS-26-28XB rear caliper mounting bracket
       C25Y-26-251B rear rotor
     All the other existing brake parts not being replaced will be reused (such as
     the brake pads, which are the same). Cars with 15" wheels may have
     clearance issues with the larger brakes.

      In addition, you can also upgrade to the 320mm front brakes used in the
     MazdaSpeed3. The following parts are needed:
       B3YF-33-61X right front caliper
       B3YF-33-71X left front caliper
       B3YF-33-28X front caliper mounting bracket (need 2)
       B37F-33-233 front caliper bracket spring (need 2)
       B37F-33-25XA front rotor
       B3YF-33-23Z front brake pad set
     You may also want to match the much larger front brakes with the 302mm
     rear brakes from the Mazda5 (any parts not listed are reused):
       C2Y6-26-28XA rear caliper mounting bracket (need 2)
       CCY9-26-61X right rear caliper
       CCY9-26-71X left rear caliper
       C26Y-26-251A rear rotor
     You could also upgrade these parts to improve responsiveness and braking
     effectiveness:
       BAYR-43-80ZA brake booster
       B3YF-43-40ZA master cylinder
       BAYR-43-55ZA brake fluid reservoir


How do I do a rear drum brake to disc brake conversion?

    Very few if not any have done this conversion. You will need to get the
    rotors, caliper, e-brake cable, spindle, and hub assemblies. You may also
    need a master cylinder or brake proportioning valve from a 4 disc brake
    car.

    1st generation owners can swap to rear disc brakes, however the initial
    stopping power from 4 disc cars perform less than the rear drum ones!
    On the other hand, the advantage to the disc brakes are better cooling
    power and better
brake modulation. Although the rear drum cars have
    better stopping power,
brake fade maybe a problem after hard driving.

    For 1st and 2nd generation owners to swap their rear brakes to discs,
    the whole rear spindles as well as the actual brakes will have to be
    swapped. The brake hoses, parking brake cables, and the proportioning
    valve will have to be swapped also. The master cylinder does not have to
    be changed unless your car has an automatic transmission. It is also
    advisible to upgrade the front brakes to maintain brake balance. The
    front rotor, front calipers, and front spindles  needs to be swapped. Cars
    that have 4 wheel disc brakes have the larger front brakes. 1st generations
    that come with 4 wheel disc brakes are the LX, GT, and 4WD models.
    Only the 2nd generation ES's come with 4 wheel disc brakes.

    3rd generation owners will break down as follows:
     4 lug cars:
     All US version 4 lug cars have front discs and rear drums. Swapping to 
     rear discs is not impossible, but quite difficult due to parts 
     availability. The rear rotors and hubs will have to be imported from an
     overseas 323 or Familia with 4 lugs. The front discs can be swapped with
     the larger 10.2" ones from a 1999-2000 ES or 2002 DX/LX.
     The front brake brake rotors and calipers from the larger front brake car
     is strongly recommended. Tthe following parts needed to perform the swap
     properly (this assumes you have performed the front brake upgrade):

       BJ3K-26-261 dust shield (must be imported), need 2
       9975-61-016 3 per side (dust shield mounting bolts)
       BKZT-26-98Z right side caliper (includes mounting bracket, caliper bolts)
       BKZT-26-99Z left side caliper (includes mounting bracket, caliper bolts)
       9975-61-035 caliper mounting bracket bolts 2 per side
       BK1T-43-980 brake line (same for both sides)
       B001-43-694A banjo bolt
       9956-21-000 banjo bolt washers, 2 per side
       GE7C-44-410D right side ebrake cable
       GE7C-44-420D left side ebrake cable
       GA2B-44-375A ebrake cable clips
       B26Y-26-251 rear brake rotor (must be imported)
       GJ21-33-042B wheel hub nut (can be reused from drum brake hub)
       BKYT-26-43ZB pad set
       B455-26-071 hub cap (can be reused from drum brake hub)
     The following are for non-ABS equiped cars:
       BK1T-26-111 rear right spindle hub/knuckle (must be imported)
       BK1T-26-115 rear left spindle hub/knuckle (must be imported)
       B455-26-15XB wheel hub (can be reused from drum brake hub)
     The following are for ABS equiped cars (wheel sensors to be reused):
       BJ3K-26-111 rear right spindle hub/knuckle (must be imported)
       BJ3K-26-115 rear left spindle hub/knuckle (must be imported)
       B603-26-15XC wheel hub (can be reused from drum brake hub)

     If you have a 1.6l car, it is recommended that you upgrade the maser cylinder,
     brake booster, and proportioning valve from the 4 disc car also.
       BJ4T-43-40Z master cylinder (for non-ABS eqiped cars)
       BJ3K-43-40Z master cylinder (for ABS equiped cars)     
       BL8M-43-800 brake booster
       B26K-43-900 proportioning valve

     I do not recommend performing this swap with all new parts as it will be
     extremely expensive. Pull most of those parts off of a wrecked 4 wheel
     disc brake Protegé and get the rest that aren't available.

     You can also get the larger European brakes instead, substituting some of the
     the parts listed above:
       GEZC-26-98ZA right side caliper (includes mounting bracket, caliper bolts)
       GEZC-26-99ZA left side caliper (includes mounting bracket, caliper bolts)
       GGYB-26-43Z rear brake pad set (same as MazdaSpeed Protegé's)
       BW2J-43-900C proportioning valve
       BL4G-43-800 brake booster
      Or if you prefer to purchase the calipers with brake pads preinstalled:
       GE7C-26-980B right side caliper (includes bracket, caliper bolts, and pads)
       GE7C-26-990B left side caliper (includes bracket, caliper bolts, and pads)

     5 lug cars:
     By far the most painless to deal with. Rear discs are already part of your
     car. StopTech and RR Racing sells big brake kits for the front.


Are there any master cylinder upgrades available?

    The 92-95 929 master cylinder is said to fit Protegé's without major issues.

My manual recommends DOT 3 brake fluid, is it safe to use DOT 4 or 5?
    The manual recommends what meets safety requirements for brakes to 
    function effectively. DOT 4 just has a higher boiling point than DOT 3, 
    and is 100% compatible with DOT 3 systems. DO NOT use DOT 5, it is
    silicone
based and will cause damage to your brake system due to seals
    incompatability! DOT 5 only has a
slightly better advantage in boiling point
    than DOT 4, but bleeding and
flushing the brake system is very difficult.
    DOT 5.1 fluid which is also
glycol based and not silicon based will also
    work fine. The difference between DOT 5.1 and DOT 4 is that DOT 5.1
    has a lower pour point than DOT 4, which means ABS systems can
    operate more effectively in extremely low temperatures. It may also serve
    easier clutch operation because of this also. Nonetheless, the boiling point
    of DOT 5.1 fluid is typically similar to DOT 4.

    Mazda Europe recommends either DOT 3 or DOT 4 brake fluid and a
    fluid change interval every 40,000km/25,000 miles or 24 months
    (whichever comes first). They go further to say that if the brakes are used
    extensively or the car is driven in extremely humid climates, it should be
    changed annually. Remember, brake fluid changing means flushing the entire
    brake system with 1 pint (500mL) of brake fluid using the same method as
    brake bleeding.

Is there a special "break-in" procedure when I upgrade my brakes?
    In a way, yes. Rather than repeating something that has been explained,
    our Nissan friends have all the answers. Nissan you say? Don't worry about
    the name "Nissan", brakes are brakes you know. This means it applies to
    all cars. Go here for a geek's reference to brakes:
    http://www.sentra.net/tech/brake_modifications.shtml



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