Mitsubishi Montero (2002-2004). Manual — part 1026

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-129

CAUTION

Do not apply excessive grease. Excessive grease may
cause brake performance to become poor.
5. For rear disc bake, apply brake grease SAE J310, NLGI

number 1 to the following positions before installing the pad.

• Pad assembly and shim A contact surface

• Inner shim A and shim B contact surface

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

drag force.

• FRONT: Refer to

P.35A-140

.

• REAR: Refer to

P.35A-146

.

DISC BRAKE ROTOR CHECK

M1351002900215

CAUTION

Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following condi-
tions should be checked:

AC000886

SHIM A

SHIM B

PAD ASSEMBLY

<REAR>

AD

INSPECTION ITEM

REMARK

Scratches, rust, saturated lining
materials and wear

• If the vehicle is not driven for a long period of time, sections of the

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

• If grooves and scratches resulting from excessive disc wear are not

removed prior to installing a new pad assembly, there will be
inadequate contact between the disc and the lining (pad) until the
pads conform to the disc.

Run-out

Excessive run-out of the discs will increase the pedal depression
resistance due to piston kickback.

Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,

shuddering and surging.

Warping (flatness) or distortion

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

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-130

BRAKE DISC THICKNESS CHECK

M1351002400254

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

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

FRONT BRAKE DISC
Standard value: 26.0 mm (1.02 inch)
Minimum limit: 24.4 mm (0.96 inch)
REAR BRAKE DISC
Standard value: 22.0 mm (0.87 inch)
Minimum limit: 20.4 mm (0.80 inch)

NOTE: 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 a on-car type brake lathe. If this step is
not carried out, the brake disc run-out will exceed the
specified value, resulting in judder.

• When the on-car type lathe is used, first install a 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 without a M12 flat washer, the
brake disc rotor may be deformed, resulting in inaccu-
rate 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.

3. If the disc thickness is less than the limits, replace it with a

new one. If thickness variation exceeds the specification,
turn rotor with an on-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.

BRAKE DISC RUN-OUT CHECK AND
CORRECTION

M1351009400404

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. Fix the disc with a hub nut temporarily.

ACX00668

AC005154 AB

M12 PLANE
WASHER

M12 PLANE
WASHER

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-131

4. Place a dial gauge approximately 5 mm (0.2 inch) from the

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

Limit: 0.06 mm (0.002 inch)

5. If the run-out of the brake disc is limit value or more, correct

it as follows:

(1) Place a mating mark on both the wheel stud and disc with

chalk where the run-out is greatest.

(2) Remove the brake disc. Then place a dial gauge as

shown in the illustration, and then move the hub in the
axial direction and measure the play.

Limit: 0 mm (0 inch)

(3) If the play exceeds the limit, disassemble the hub and

knuckle assembly to check each part.

(4) If the play does not exceed the limit, install the brake disc

at a different phase, and then check the run-out of the
brake disc again.

CAUTION

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

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

• When the on-car type lathe is used, first install a 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 without a M12 flat washer, the
brake disc rotor may be deformed, resulting in inaccu-
rate 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.

6. If the run-out cannot be corrected by changing the phase of

the brake disc, replace the brake disc or turn rotor with an
on-car type brake lathe ("Accuturn-8750" or equivalent).

ACX00669

ACX00670

AC005154 AB

M12 PLANE
WASHER

M12 PLANE
WASHER

BRAKE PEDAL

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BASIC BRAKE SYSTEM

35A-132

BRAKE PEDAL

REMOVAL AND INSTALLATION

M1351003400257

INSTALLATION SERVICE POINT

.

>>A<< BRAKE PEDAL AND PEDAL SUPPORT MEMBER
ASSEMBLY INSTALLATION
Tighten the brake booster mounting nut ("A" in the illustration)
first, then tighten the brake pedal mounting bolt ("B" in the illus-
tration).
NOTE: Because the mounting hole of the pedal mounting bolt
("B" in the illustration) is a slotted hole, if the pedal mounting
bolt ("B" in the illustration) is mounted first, positioning
becomes impossible.

Post-installation Operation
• Brake Pedal Adjustment (Refer to

P.35A-115

.)

ACX01838 AB

14 ± 3 N·m
124 ± 26 in-lb

12 ± 2 N·m
107 ± 17 in-lb

1

2

N

N

3

4

5

6

7

8

9

10

11

12

REMOVAL STEPS

•

INSTRUMENT PANEL LOWER
PANEL (REFER TO GROUP 52A,
INSTRUMENT PANEL

P.52A-2

.)

1.

RETURN SPRING

2.

COTTER PIN

3.

SHIFT LOCK CABLE
CONNECTION

4.

HARNESS CONNECTOR

5.

STOPLIGHT SWITCH

6.

ADJUSTER

7.

PEDAL STOPPER

8.

SNAP PIN

9.

CLEVIS PIN

10.

PEDAL PAD

11.

BRAKE BOOSTER MOUNTING
NUT

>>A<<

12.

BRAKE PEDAL AND PEDAL
SUPPORT MEMBER ASSEMBLY

REMOVAL STEPS (Continued)

ACX01839 AB

A

A

B