Mitsubishi Montero Sport (2004+). Manual — part 774

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-21

3. Remove the following parts from caliper support.

(1) Pad and wear indicator assembly
(2) Pad assembly
(3) Clip
(4) Outer Shim

4. Measure the hub torque before and after pad installation.

Follow the procedure:
Refer to

P.35A-31

.

5. Install the pad and caliper assembly, and check the brake

drag force. (Refer to

P.35A-31

.)

DISC BRAKE ROTOR CHECK

M1351002900356

CAUTION

When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the
allowable service values in order to maintain normal brake operation.
Before turning the brake disc, the following conditions should be checked.

AC004365AB

3

4

2

3

1

INSPECTION ITEMS

REMARKS

Scratches, rust, saturated lining materials and wear

• If the vehicle is not driven for a certain period, the

sections of the discs that are not in contact with
lining will become rusty, causing noise and
shuddering.

• If grooves resulting from excessive disc wear and

scratches are not removed prior to installing a
new pad assembly, there will momentarily be
inappropriate contact between the disc and the
lining (pad).

Run-out or drift

Excessive run-out or drift of the discs will increase
the pedal depression resistance due to piston
knock-back.

Change in thickness (parallelism)

If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.

Inset or warping (flatness)

Overheating and improper handling while servicing
will cause inset or warping.

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-22

FRONT BRAKE DISC RUN-OUT CHECK AND
CORRECTION

M1351009400493

1. Remove the caliper support; then raise the caliper assembly

upward and secure it with a wire.

2. Inspect the disc surface for grooves, cracks and rust. Clean

the disc thoroughly and remove all rust.

3. Place a dial gauge approximately 15 mm (0.6 inch) from the

outer circumference of the brake disc, and measure the
run-out of the disc.

Limit: 0.03 mm (0.001 inch)

CAUTION

• After a new brake disc is installed, always grind the

brake disc with on-the-car type brake lathe. If this step
is not carried out, the brake disc run-out exceeds the
specified value, resulting in judder.

• When the on-the-car type lathe is used, first install M12

flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.

• Grind the brake disc with all wheel nuts diagonally and

equally tightened to the specified torque 100 N

⋅m (74

ft-lb). When all numbers of wheel nuts are not used, or
the tightening torque is excessive or not equal, the
brake disc rotor or drum may be deformed, resulting in
judder.

4. If the run-out of the brake disc is limit valve or more, turn

rotor with on the car type brake lathe ("Accuturn-8750" or
equivalent).
If still exceeds the limit, inspect hub end play.

Limit: 0.05 mm (0.002 inch)

5. If the play exceeds the limit, check the hub. If the play does

not exceed the limit, replace the brake disc.

AC004383 AB

CALIPER SUPPORT
MOUNTING BOLT

ACX00669

AC006226 AB

M12 FLAT WASHER

M12 FLAT WASHER

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-23

BRAKE DISC THICKNESS CHECK

M1351002400403

1. Remove dirt and rust from the brake disc surface.
2. Using a micrometer, measure disc thickness at eight

positions, approximately 45 degree angle apart and 10 mm
(0.4 inch) in from the outer edge of the disc.

BRAKE DISC THICKNESS

Standard value: 24.0 mm (0.94 inch)
Minimum limit: 22.4 mm (0.88 inch)

3. Thickness variation (at least 8 positions) should not be more

than 0.015 mm (0.0006 inch).

CAUTION

• After a new brake disc is installed, always grind the

brake disc with on-the-car type brake lathe. If this step
is not carried out, the brake disc run-out exceeds the
specified value, resulting in judder.

• When the on-the-car type lathe is used, first install M12

flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.

• Grind the brake disc with all wheel nuts diagonally and

equally tightened to the specified torque 100 N

⋅m (74

ft-lb). When all numbers of wheel nuts are not used, or
the tightening torque is excessive or not equal, the
brake disc rotor or drum may be deformed, resulting in
judder.

4. If the disc thick is less than 22.4 mm (0.88 inch) thick,

replace it with a new one. If thickness variation exceeds the
specification, turn rotor with an on-the-car type brake lathe
("Accuturn-8750" or equivalent).
If the calculated final thickness after turning the rotor is less
than the standard value, replace the disc.

ACX00668

AC006226 AB

M12 FLAT WASHER

M12 FLAT WASHER

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-24

BRAKE LINING THICKNESS CHECK

M1351003000378

CAUTION

• Whenever the shoe and lining assembly is replaced,

replace both RH and LH assemblies as a set to prevent
the car from pulling to one side when braking.

• If there is a significant difference in the thickness of the

shoe and lining assemblies on the left and right sides,
check the sliding condition of the piston.

1. Remove the brake drum.
2. Measure the thickness of the brake lining at the place worn

the most.

Standard value: 4.7 mm (0.19 inch)
Minimum limit: 1.0 mm (0.04 inch)

Replace the shoe and lining assembly if brake lining thickness
is less than the limit or if it is not worn evenly. For information
concerning the procedures for installation of the shoe and lining
assembly, refer to

P.35A-37

.

BRAKE DRUM INSIDE DIAMETER CHECK

M1351003200543

1. Remove the brake drum.
2. Measure the inside diameter of the brake drum at two or

more locations.

Standard value: 270.0 mm (10.63 inches)
Limit: 272.0 mm (10.71 inches)

3. Replace the brake drums, shoe and lining assembly when

wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM CONTACT
CHECK

M1351003100364

1. Remove the brake drum.
2. Remove the shoe and lining assembly. (Refer to

P.35A-37

.)

3. Chalk the inner surface of the brake drum and rub with the

shoe and lining assembly.

4. Replace the shoe and lining assembly or brake drums if

there are any irregular contact area.
NOTE: Clean off chalk after check.

AC004387 AB

AC004388 AB

AC004407 AB