Mitsubishi Montero (2002-2004). Manual — part 1031
REAR DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-149
LUBRICATION POINTS
DISASSEMBLY SERVICE POINTS
CAUTION
When disassembling the disc brakes, disassemble both
sides (left and right) as a set.
.
AC205297AB
PISTON
SEAL
BRAKE FLUID: DOT3 OR DOT4
GREASE: REPAIR KIT GREASE
GREASE: BRAKE GREASE J310, NLGI NO.1
GREASE: REPAIR KIT GREASE
THE PISTON SEAL INSIDE THE SEAL
AND BOOT KIT IS COATED WITH
SPECIAL GREASE. DO NOT WIPE
THIS GREASE OFF.
CAUTION
PAD ASSEMBLY
SHIM A
SHIM B
REAR DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-150
<<A>> PISTON BOOT/PISTON REMOVAL
CAUTION
Blow air little by little to remove the piston. The piston will
rush out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown.
Blow compressed air through the brake hose connection hole
to remove the piston boot and piston.
.
<<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 piston surface and inner cylinder with alcohol or brake
fluid DOT 3 or DOT 4.
ASSEMBLY SERVICE POINT
.
>>A<< LOCK PIN/GUIDE PIN INSTALLATION
Attach a guide pin at the bleeder nipple side of the caliper body
and a lock pin at the opposite side.
AC204331
AC204684
AC204734 AB
GUIDE PIN
LOCK PIN
BLEEDER
NIPPLE
REAR DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-151
INSPECTION
M1351007300177
• 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 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
AC204733
SPECIFICATIONS
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BASIC BRAKE SYSTEM
35A-152
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1351009600260
GENERAL SPECIFICATIONS
M1351000200210
ITEM
SPECIFICATION
Brake line
Brake tube flare nut
15
± 2 N⋅m (11 ± 2 ft-lb)
Brake pedal
Hydraulic brake booster mounting nut
14
± 3 N⋅m (124 ± 26 in-lb)
Pedal support member mounting bolt
12
± 2 N⋅m (107 ± 17 in-lb)
Buzzer
Buzzer mounting nut
5.0
± 1.0 N⋅m (44 ± 9 in-lb)
Hydraulic brake booster (HBB)
Accumulator
54
± 5 N⋅m (40 ± 4 ft-lb)
Brake tube flare nut (between master cylinder and pump motor)
15.2
± 3 N⋅m (11 ± 2 ft-lb)
Clevis nut
25.5
± 5.1 N⋅m (19 ± 3 ft-lb)
Hydraulic brake booster mounting nut
14
± 3 N⋅m (124 ± 26 in-lb)
Lead wire screw (hydraulic unit side)
1.7
± 0.1 N⋅m (15 ± 1 in-lb)
Lead wire screw (pump motor side)
3.0
± 0.5 N⋅m (26 ± 4 in-lb)
Pump motor bracket mounting bolt
11.8
± 2.3 N⋅m (104 ± 20 in-lb)
Pump motor mounting bolt
7.8
± 1.5 N⋅m (69 ± 13 in-lb)
Reservoir assembly mounting screw
1.7
± 0.3 N⋅m (15 ± 2.6 in-lb)
Front disc brake
Bleeder screw
7.4
± 1.4 N⋅m (65 ± 13 in-lb)
Brake hose connector bolt
30
± 4 N⋅m (22 ± 3 ft-lb)
Front brake assembly mounting bolt
113
± 9 N⋅m (83 ± 7 ft-lb)
Guide pin
89
± 4 N⋅m (66 ± 3 ft-lb)
Guide pin lock bolt
89
± 4 N⋅m (66 ± 3 ft-lb)
Rear disc brake
Bleeder screw
7.9
± 0.9 N⋅m (70 ± 8 in-lb)
Brake hose connector bolt
30
± 4 N⋅m (22 ± 3 ft-lb)
Rear disc brake assembly mounting bolt
100
± 10 N⋅m (74 ± 7 ft-lb)
Guide pin
44
± 5 N⋅m (33 ± 3 ft-lb)
Lock pin
44
± 5 N⋅m (33 ± 3 ft-lb)
ITEM
SPECIFICATION
Hydraulic brake
booster (HBB)
Master cylinder type
Single type (with center valve)
Master cylinder ID mm (in)
22.22 (0.875)
Boosting ratio
5.4
Rear wheel hydraulic pressure control type
Electronic brake-force distribution (EBD)
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