Mitsubishi Montero (2002-2004). Manual — part 1030
FRONT DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-145
INSPECTION
M1351006300248
• 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)
ACX00690
REAR DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-146
REAR DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION
M1351007000187
Required Special Tool:
• MB990520: Disc Brake Piston Expander
INSTALLATION SERVICE POINT
.
>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure brake drag torque after pad installation,
measure hub torque with the pads removed.
Use a spring scale to measure hub torque in the direction
shown. Record the value.
CAUTION
Do not allow any oil, grease or other contamination to con-
tact the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support, install the pad clips
and pads to the caliper support.
Pre-removal Operation
• Brake Fluid Draining
Post-installation Operation
• Brake Fluid Supplying and Air Bleeding (Refer to
AC204328
AB
100 ± 10 N
•
m
74± 7 ft-lb
30 ± 4 N
•
m
22 ± 3 ft-lb
1
2
3
4
N
REMOVAL STEPS
1. BRAKE HOSE CONNECTION
2. GASKET
>>A<<
3. DISC BRAKE ASSEMBLY
4. BRAKE DISC
ACX00692
REAR DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-147
3. Clean the piston, and insert it into the cylinder with special
tool MB990520.
4. Be careful that the piston boot does not become caught
when lowering the caliper assembly and installing the guide
pin.
5. Check brake drag force as follows:
(1) Start the engine and hold the brake pedal down for five
seconds. [Pedal depression force: approximately 196 N
(44 pounds)]
(2) Stop the engine.
(3) Turn the brake disc forward ten times.
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value: 55 N (12 pounds)
6. If the drag torque exceeds the standard value, disassemble
and clean the piston. Check for corrosion or worn piston
seal, and check the sliding condition of the lock pin and
guide pin.
INSPECTION
M1351007100184
Brake Disc Check
• Disc wear (Refer to
• Disc run-out (Refer to
ACX00693AB
MB990520
ACX00694
REAR DISC BRAKE ASSEMBLY
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BASIC BRAKE SYSTEM
35A-148
DISASSEMBLY AND ASSEMBLY
M1351007200181
AC204380AB
44 ± 5 N
•
m
33 ± 3 ft-lb
1
1
17
17
7.9 ± 0.9 N
•
m
70 ± 8 in-lb
12
12
12
12
9
9
10
10
10
12
12
16
16
16
15
15
14
14
14
13
13
13
6
6
6
6
6
6
2
5
5
5
4
4
4
3
3
3
11
11
CLIP SET
BRAKE CALIPER KIT
PAD SET
SHIM SET
SEAL AND BOOTS KIT
N
N
N
N
8
7
8
7
8
7
DISASSEMBLY STEPS
>>A<<
1. GUIDE PIN
2. PAD AND CLIP ASSEMBLY AND SHIM
3. SHIM
4. PAD AND CLIP ASSEMBLY
5. PAD ASSEMBLY
6. PAD CLIP
7. SHIM B
8. SHIM A
>>A<<
9. LOCK PIN
10. BUSHING
11. CALIPER SUPPORT
12. PIN BOOT
13. BOOT RING
<<A>>
14. PISTON BOOT
<<A>>
15. PISTON
<<B>>
16. PISTON SEAL
17. CALIPER BODY
DISASSEMBLY STEPS (Continued)
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