I have a 2002 Mazda protégé LX 2 L engine manual transmission for which I attempted to replace the brake pads. Upon unbolting the caliper, it appeared as though the piston was pressing in beyond the boundaries Of the caliper assembly thereby not allowing me to remove the caliper to expose the worn brake pads. Could this be because the brake pads are so worn that the piston has to press them in farther than usual to make contact? In any case is there someway that I can alleviate the situation so that I can proceed with the brake pad replacement? Thank you!

 

Cliff:

You are right it is possible that you went beyond the designed path of the caliper pistons. This is in particular possible if the rotor has been worn down as well. The rotor would have a lip on the outer edge.

Try to put a small flat screw driver or similar between the rotor and the pad (or what's left of it) then follow up with a prybar and push it back.

It will probably be necessary to replace the rotor and pads. If you are lucky the calipers have survivied.
Take the sliders off and inspect them for corrosion. Clean them of the corrosion and lube them with caliper grease.
Replace the brake fluid, same as bleeding but you go until new fluid comes out of the bleeder.

 

Thanks so much for the response! I did identify a lip on the edge of the rotor. I will attempt to pry the pads off like you suggested. Will this lip of the rotor harm the new pads at all? Thanks

 

Yes the lips can cause problems.

3 options,

1 get the disc's machined
2 replace the rotors
3 chamfer the edges of the new pad.