Mitsubishi L200. Manual — part 412

ON-VEHICLE SERVICE

BASIC BRAKE

35A-12

1. Visually check the thickness of brake pad from the

inspection hole of the caliper body.

Standard value: 9.5 mm
Limit: 1.5 mm

2. If the brake pad thickness is less than the limit

value, replace the brake pad (Refer to

P.35A-12

).

BRAKE PAD REPLACEMENT

M1351017400681

CAUTION

When replacing, replace both brake pads (right
and left) as a set.

AC502284AB

1. Remove the parts indicated in the figure, swivel

the caliper body upward and retain it with a wire or
similar tool.

AC903812

<Right side>

<Left side>

Vehicle out side

AB

2

3

1

5

5

1

Wear indicator

Vehicle out side

2

3

1

5

5

1

Vehicle out side

Vehicle out side

<Right side>

<Standard brake pads>

<Low steel brake pads>

<Left side>

1

3

5

5

1

3

4

Wear indicator

1

3

5

5

1

3

4

<Right side>

<Left side>

Vehicle out side

3

1

5

5

1

Wear indicator

Vehicle out side

3

1

1

5

5

<2WD (except High rider)>

<2WD (High rider), 4WD>

ON-VEHICLE SERVICE

BASIC BRAKE

35A-13

2. Remove the following parts from the caliper body.

(1) Shim
(2) Shim cover
(3) Brake pad assembly
(4) V spring

(5) Clip

NOTE: The brake pad assembly with wear indicator
is installed only to the inner side of the brake disc of
the left-side brake at factory.

ON-VEHICLE SERVICE

BASIC BRAKE

35A-14

CAUTION

Keep grease or other soiling off the pad and
brake disc friction surfaces.

AC706162AB

MB990520

Piston

Caliper body

3. Clean the piston part, and press the piston into

the cylinder using the special tool piston expander
(MB990520).

4. Assemble the shim, shim cover, brake pad

assembly, v spring and clip to the caliper support,
and tighten the pin bolt to the specified torque.

Tightening torque: 27

± 4 N⋅m

NOTE: Install the brake pad assembly (with wear
indicator) to the inner side of the brake disc, mak-
ing sure that the wear indicator is located on the
bottom.

LUBRICATION POINT

AC803004AC

Grease: Repair kit grease (Colour: Translucent
red), Niglube RX-2 or equivalent

BRAKE DISC CHECK

M1351018600138

BRAKE DISC THICKNESS CHECK
1. Remove contaminants or corrosion from the brake

disc surface.

ACX00668AH

Approx. 10 mm

2. Use a micrometer to measure the brake disc

thickness at minimum eight points which are 10
mm inward from its circumference.

Standard value: 28.0 mm
Limit: 26.4 mm

3. If the brake disc thickness is worn beyond the limit

value at more than one point, replace the brake
disc and check its run-out.

BRAKE DISC THICKNESS UNEVENNESS CHECK
AND CORRECTION
1. Remove contaminants or corrosion from the brake

disc surface.

ACX00668AH

Approx. 10 mm

2. Use a micrometer to measure the brake disc

thickness at minimum eight points which are 10
mm inward from its circumference. Then record
the measurements.

3. If the brake disc thickness unevenness (the

difference between the maximum and minimum
values measured above) is 0.015 mm or less, it is
within the standard value.

4. If the brake disc thickness unevenness exceeds

the standard value, grind it according to the
procedure below while it is mounted on the
vehicle.
NOTE: If it is suspected that the brake disc thick-
ness will become less than the limit value after the
grinding, replace the brake disc and check its run-
out.

ON-VEHICLE SERVICE

BASIC BRAKE

35A-15

(1) Check for wheel bearing looseness in the axial

direction (Refer to GROUP 26

− On-vehicle

Service, Wheel bearing axial play check ).

CAUTION

•

AC006226 AE

M12 Flat washer

M12 Flat washer

Insert M12 plain washer and then install the

adapter as shown before grinding. Failure to
use the M12 plain washer will cause the brake
disc to be deformed and ground incorrectly.

• To grind the brake disc, ensure that all the

nuts (M12 X 1.5) are tightened evenly and in a
diagonal sequence to the specified torque
(100 N

⋅m). Failure to use all the nuts

(M12

×1.5), excessive or uneven tightening

torque will cause the brake disc to deform or
judder.

(2) Correct the brake disc uneven thickness by

grinding it while in place on the vehicle.

BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Check for wheel bearing looseness in the axial

direction (Refer to GROUP 26

− On-vehicle

Service, Wheel bearing axial play check ).

2. If the axial play is within the limit value, secure the

brake disc by tightening the nut (M12

×1.5) evenly

to the specified torque (100 N

⋅m).If the axial play

still exceeds the limit value, replace the wheel
bearing. Then secure the brake disc by tightening
the nut (M12

×1.5) evenly to the specified torque

(100 N

⋅m).

ACX00669AG

Approx. 5 mm

3. Place a dial gauge ca. 5 mm inward from the

circumference of the brake disc to measure its
run-out.

Limit: 0.06 mm

4. If the brake disc run-out exceeds the limit value,

rephase the brake disc to the hub so that the
minimum brake disc run-out is obtained.