Specifically the outside pad.

So I managed to get the old pads out, prepared the new ones with anti squeal etc. Then tried to insert the new outside pad, and it didn't fit in the space between the housing and the rotor.

So does anyone have any idea on how I can fit that in? Short of dismantling the caliper etc.?

It's a '94 Mazda Familia, chassis type BH, engine Z5.

See the picture attached, where I circled in red. Thanks!

 

which pads did you use? did you push the caliper all of the way open? if it got pushed all of the way open, the caliper should slide from side to side easily and the pot(s) shouldn't be showing much of any metal.

i have used some pads in the past that didn't fit right. i can't remember the brands, but they had built-in shims and were ceramic type. the caliper could be seized up a little also.

 

I used aftermarket ones. I pushed the piston almost all the way in, perhaps leaving an inch left.

The caliper is fixed and doesn't move. To replace the pads you only need to move the clips, and the two horizontal bolts then you can pull the pads off.

However I couldn't fit the new pad to replace the pad circled in red.

The pads that are on the car have built-in shims etc. and look exactly the same as the new ones.

 

You probably just need to compress the piston fully. That should give you more travel on the caliper. The caliper can't be "fixed", or your brakes wouldn't work.

 

the caliper isn't fixed in that way. it is fixed where it doesn't swing open like my protege calipers. that is the same way my rx7 calipers are. i think that the caliper is seized up or hasn't been pushed open enough.

 

also, the caliper should slide toward and away from you when you are sitting on the side of the car, facing the rotor. if it doesn't slide at all, it is partially seized on that side. that's not affecting opening the caliper, but it is showing that there are problems. the caliper may need to be rebuilt.

 

Right, thanks for your comments and help guys. So the caliper can actually move as the outside pad will need to touch the rotor when the brake pedal is pressed. I haven't actually seen the whole thing in operation ...

I've attached another picture, and to be able to install the outside pad I will need to move the caliper (the section outlined in yellow) to the direction where the arrows are pointing..... Correct?

 

Don't forget to cut rotors

 

You can check for brake pad wear by viewing the pads from outside the front tire. On most cars, you can look through the openings on the outside of the wheel. You may have to remove the wheel to see the pads.
If the pad depth is less than ¼ inch, plan on replacing it soon. If it's less than 1/8 inch, you're getting close to damaging the rotor, so do it ASAP. This varies slightly from car to car, but is a good general guideline.