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It could be a faulty brake master cylinder though your description does remind me of a car that had the disc pads wrongly fitted and the anti-rattle springs were pushing the pads away from the discs instead of providing resistance.
A similar symptom can be experienced when a wheel bearing has excess free play and pushes the pads away from the disc.
I would use a hose clamp and isolate each brake in turn until the brake pedal operation is normal. If no clamping operation makes a significant difference I would then clamp two, three and then four hoses when if there is still no difference I would suspect the master cylinder or the basic brake pedal and servo adjustments.
The brake lining's have worn away, the squealing was metal to metal (worn pad against metal disc) The worn pad will have damaged the brake disc. Very dangerous. You will now have to have new brake pads and discs fitted to BOTH front wheels to put it right. Good luck
remove caliper, push disc all way home, put wheel nut on to hold home, retry fitting them the disc may be slightly scued. If no go try diffrent brand of pad I had same prob with a diffrent car last week & diffrent brand pad was 2mm thiner. If can't exchange pads get piece of emery paper on flat surface & sand away top part of pad material in round motions both ways till they fit. :-)
Hi, Brake Padsare an important part of your Mazda6's braking system. They are the replaceable friction pads that pinch the brake disc or drum when the brakes are applied. You should replace the brake pads before they wear beyond a quarter inch or risk damaging your Mazda6's brake discs. Instructions Remove the old Brake Pads
Step 1 Park your car on a level surface. If you have a stick shift car, make sure the car is in gear. Do not set the parking brake. Place blocks in front of the front tires so the car does not move while you are working on it.
Step 2 Open the hood of your car. Locate the master cylinder and brake fluid container. If necessary, remove brake fluid until the level in the container is less than half full. A turkey baster is a good tool for this. Put the brake fluid in the plastic container and dispose of it the way you dispose of motor oil.
Step 3 Raise the rear end of your car with your car jack. Remove the rear tire or wheel assembly.
Step 4 Disconnect the parking brake cable from the brake caliper. The cable is usually held in place with a retaining clip. You can use pliers to remove the clip and disconnect the cable.
Step 5 Remove the upper caliper bolt. Rotate the caliper downward until you can comfortably work on it. Remove the springs, pads and shims from the caliper.
Install the new Brake Pads
Step 1 Use the recommended tool to press the caliper piston back into the piston assembly.
Step 2 Insert the shims, springs and new pads into the caliper. Reconnect the parking brake cable.
Step 3 Rotate the caliper upward and back into place. Use the socket wrench to tighten the upper mounting bolt to 27 to 36 foot lb. (37 to 49 Nm) if you have a Mazda6 or to 16 to 23 foot lb. (21 to 31 Nm) if you have a Mazdaspeed6.
Step 4 Replace the tire wheel assembly. Lower the car to the ground.
Step 5 Add fluid to the master cylinder container to replace any you removed before you removed the old brake pads.
Step 6 Season the brake pads by making only gentle stops when you are driving for the first week after you install the new brake pads. Try not to do any hard stopping when you are seasoning the brakes.
The hard part is pressing the caliper piston abck into the caliper so you can get the new, thicker pads over the rotor. A large C Clamp works best.
SECTION 206-03: Front Disc Brake
2001 Villager Workshop Manual
REMOVAL AND INSTALLATION
Pads —Front Disc Brake
Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
Remove the front disc brake caliper bolts. torx bit. T20?
Support the front disc brake caliper from the front strut and spring assembly using mechanics wire.
Remove the front disc brake pads.
Remove the outboard front disc brake pad.
Remove the inboard front disc brake pad.
CAUTION: Make sure the master cylinder reservoir does not overfill and spill brake fluid while retracting the front disc brake caliper piston. NOTE: It is necessary to fully retract the front disc brake caliper piston in the bore before installing the front disc brake pads. Install the front disc brake pads.
Install the inboard front disc brake pad.
Install the outboard front disc brake pad.
Caution. The outer pads are left and right. put left on driver side.
Position the front disc brake caliper on the front-wheel knuckle and install the brake caliper pin bolts.
WARNING: It is necessary to depress the brake pedal several times to position the front disc brake caliper piston before driving the vehicle.