04-003/04 2004 MAZDA3 - SQUEAK NOISE FROM REAR BRAKES

Note: This bulletin contains revised sections. Please update your records accordingly.

BULLETIN NOTE

• This bulletin supersedes last issued 05/03/2004. The REPAIR PROCEDURE has been revised.

APPLICABLE MODEL(S)/VINS

2004 Mazda3 with 15" wheels With VINs lower than JM1 BK **** 41 131014

2004 Mazda3 with 16" or 17" wheels With VINs lower than JM1 BK **** 41 130969

DESCRIPTION

Some customers may hear a squeaking noise coming from the rear brakes when starting the vehicle from a stop, or, during light brake pedal application.

The rear brake pad on the mounting (ie: caliper) support may not fit straight due to burrs. Because of this, the rear brake pad partially contacts the disc plate, causing the squeak noise. The concern can also occur if the parking brake is improperly adjusted.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Disassemble the rear brake calipers from the vehicle and remove the mounting supports and pads. Refer to Workshop Manual (section 04-11 REAR BRAKE (DISC) REMOVAL/INSTALLATION).

3. File the corners of the pads.

   NOTE: Use an extra fine steel file available at local hardware stores.

   1. Remove burrs from the contact surface between all pads and mounting supports.

      NOTE: Be sure to file both inner and outer edges.

   2. Run finger along edges of the pads and make sure you don't feel any burrs.

      NOTE: It is not necessary to over file as long as no burrs are felt.

4. File mounting supports.

5. Apply grease sparingly to pads, as shown, where it contacts the mounting supports. There are four locations per pad.

   NOTE: Use high temperature, anti-seize lubricant, Permatex P/N 133AR (available at a local automotive parts store), or equivalent.

6. Reassemble brake pads and mounting supports.

7. Adjust lever of the parking brake until a click is heard 3 to 6 times when pulled up hard (approximately 10 kg / 22 lb). Refer to Workshop Manual (section 04-12 PARKING BRAKE LEVER ADJUSTMENT).

8. Verify repair.

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.
• Additional diagnostic time cannot be claimed for this repair.