Mitsubishi Montero Sport (2004+). Manual — part 777
FRONT DISC BRAKE ASSEMBLY
TSB Revision
BASIC BRAKE SYSTEM
35A-33
DISASSEMBLY AND ASSEMBLY
M1351006200553
AC005052 AB
SHIM KIT
CLIP KIT
SEAL AND BOOTS
REPAIR KIT
PAD SET
BRAKE CALIPER KIT
16
2
1
3
12
11
6
10
9
8
7
6 10
9
8
7
5
6
10 8
7
6
10
8
7
3
GREASE
13
14
13
14
6
10
9
8
7
6
10
9
8
7
2
1
3
12
11
13
14
15
5
16
4
15
16
8 N·m
71 in-lb
74 N·m
55 ft-lb
CALIPER ASSEMBLY
DISASSEMBLY STEPS
>>A<<
1.
LOCK PIN
>>A<<
2.
GUIDE PIN
3.
BUSHING
4.
CALIPER SUPPORT, PAD, CLIP
AND SHIM ASSEMBLY
5.
CALIPER SUPPORT
6.
PIN BOOT
7.
BOOT RING
<<A>>
8.
PISTON BOOT
<<A>>
9.
PISTON
<<B>>
10. PISTON SEAL
11. CALIPER BODY
12. BLEEDER SCREW
PAD ASSEMBLY DISASSEMBLY
STEPS
>>A<<
1. LOCK PIN
>>A<<
2. GUIDE PIN
3. BUSHING
4. CALIPER SUPPORT, PAD, CLIP AND
SHIM ASSEMBLY
13. PAD AND WEAR INDICATOR
ASSEMBLY
14. PAD ASSEMBLY
15. OUTER SHIM
16. CLIP
FRONT DISC BRAKE ASSEMBLY
TSB Revision
BASIC BRAKE SYSTEM
35A-34
LUBRICATION POINTS
AC005053 AB
GREASE: REPAIR KIT GREASE
GREASE: REPAIR KIT GREASE
GREASE: REPAIR KIT GREASE
CAUTION:
THE PISTON SEAL INSIDE THE SEAL
AND BOOT KIT IS COATED WITH A
SPECIAL GREASE. DO NOT WIPE
THIS GREASE OFF.
BRAKE FLUID: DOT3 OR DOT4
9
8
FRONT DISC BRAKE ASSEMBLY
TSB Revision
BASIC BRAKE SYSTEM
35A-35
DISASSEMBLY SERVICE POINTS
When disassembling the front disc brakes, disassemble both
sides (left and right wheels) as a set.
.
<<A>> PISTON BOOT/PISTON REMOVAL
CAUTION
• When removing the pistons, be sure to use the handle
of a plastic hammer and adjust the height of the two
pistons while pumping air slowly in so that the pistons
protrude evenly.
• Do not remove one piston completely before trying to
remove the other piston, because it will become impos-
sible to remove the second piston.
Protect the caliper body with a shop towel. Blow compressed
air through the brake hose to remove the piston boot and pis-
ton.
.
<<B>> PISTON SEAL REMOVAL
CAUTION
Do not use a flat-tipped screwdriver or similar tool to
remove piston seal. These may damage the inner side of
the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol or
the specified brake fluid DOT3 or DOT4.
ACX00688
AC004463 AB
FRONT DISC BRAKE ASSEMBLY
TSB Revision
BASIC BRAKE SYSTEM
35A-36
ASSEMBLY SERVICE POINT
.
>>A<< LOCK PIN/GUIDE PIN INSTALLATION
Install the lock pin and guide pin to the caliper body as shown in
the illustration.
INSPECTION
M1351006300419
• Check the cylinder for wear, damage or rust.
• Check the piston surface for wear, damage or rust.
• Check the caliper body or sleeve for wear.
• Check the pad for damage or adhesion of grease, check the
backing metal for damage.
.
PAD WEAR CHECK
WARNING
•
Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
•
If there is significant difference in the thickness of
the pads on the left and right sides, check the slid-
ing condition of the piston, lock pin and guide pin.
Measure thickness at the thinnest and most worn area of the
pad. Replace the pad assembly if pad thickness is less than the
limit value.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
AC004464 AB
GUIDE PIN
LOCK PIN
ACX00690
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