Mitsubishi Evolution X. Manual — part 325

MAINTENANCE SERVICE

TSB Revision

GENERAL

00-75

17. DISK BRAKE PADS AND ROTORS (INSPECT
FOR WEAR)

M1001003200440

DISK BRAKE PAD CHECK

CAUTION

If there is a significant difference in the thicknesses of the
pads on the left and right sides, check moving parts (Refer
to

P.35A-21

).

1. Visually check the thickness of brake pad from the

inspection hole of the caliper body.

Standard value:

9.85 mm (0.39 inch) <Front>
9.0 mm (0.35 inch) <Rear>

Limit:

2.0 mm (0.08 inch) <Front>
2.0 mm (0.08 inch) <Rear>

2. When the thickness is lower than the limit value, replace

both brake pads (right and left) as a set (Refer to

P.35A-18

).

DISK BRAKE ROTOR CHECK

CAUTION

Disk brakes must be kept within the allowable service val-
ues in order to maintain normal brake operation.
Before turning the brake disk, the following conditions should
be checked.

AC706942AB

<Front>

AC706943AB

<Rear>

Inspection items

Remarks

Scratches, rust, saturated lining materials and wear

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

time, sections of the disks that are not in contact
with the pads will become rusty, causing noise
and shuddering.

• If grooves and scratches resulting from excessive

disk wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disk and the lining (pad) until the
pads conform to the disk.

Run-out

Excessive run-out of the disks will increase the pedal
depression resistance due to piston kick-back.

Change in thickness (parallelism)

If the thickness of the disk changes, this will cause
pedal pulsation, shuddering and surging.

MAINTENANCE SERVICE

TSB Revision

GENERAL

00-76

.

BRAKE DISK THICKNESS CHECK

1. Using a micrometer, measure disk thickness at eight

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

Standard value:

32.0 mm (1.26 inch) <Front>
22.0 mm (0.87 inch) <Rear>

Limit:

30.0 mm (1.18 inch) <Front>
20.0 mm (0.79 inch) <Rear>

NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch).

CAUTION

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

brake disk with on-the-car type brake lathe. If this step
is not carried out, the brake disk run-out exceeds the
specified value, resulting in judder.

• When the on-the-car type lathe is used, first install M12

flat washer on the stud bolt in the brake disk side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disk rotor may be deformed, resulting in inac-
curate grinding.

• Grind the brake disk 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 disk rotor or drum may be deformed, resulting in
judder.

2. If the disk thickness is less than the limits, replace it with a

new one. If thickness variation exceeds the specification,
turn rotor with an on-the-car type brake lathe ("MAD,
DL-8700PF" or equivalent). If the calculated final thickness
after turning the rotor is less than the standard value,
replace the disk.

.

FRONT BRAKE DISK RUN-OUT CHECK AND
CORRECTION

1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disk with the hub nut.

Inset or warping (flatness)

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

Inspection items

Remarks

ACX00668 AB

AC006226 AE

M12 Flat washer

M12 Flat washer

MAINTENANCE SERVICE

TSB Revision

GENERAL

00-77

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

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

Limit:

0.06 mm (0.0024 inch) <Front>
0.08 mm (0.0032 inch) <Rear>

4. When the brake disk runout exceeds the limit value, correct

the brake disk runout according to the following procedure.

(1) Before removing the brake disk, make marks using a

chalk to the stud bolt on the side with the greater runout
and to both sides of the stud bolt.

(2) Check the wheel bearing axial looseness. (Refer to

GROUP 26

− On-vehicle Service, Wheel Bearing End

Play Check

P.26-7

<Front> or GROUP 27

− On-vehicle

Service, Wheel Bearing End Play Check

P.27-33

<Rear>.)

(3) When the looseness is within the limit value, install the

brake disk after changing the phase between the hub and
the brake disk, then check the runout of the brake disk
again.

CAUTION

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

brake disk with on-the-car type brake lathe. If this step
is not carried out, the brake disk run-out exceeds the
specified value, resulting in judder.

• When the on-the-car type lathe is used, first install M12

flat washer on the stud bolt in the brake disk side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disk rotor may be deformed, resulting in inac-
curate grinding.

• Grind the brake disk 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 disk rotor or drum may be deformed, resulting in
judder.

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

the brake disk, replace the brake disk or grind it with the
on-the-car type brake lathe ("MAD, DL-8700PF" or
equivalent).

ACX00669AB

AC201323 AD

Chalk marks

AC006226 AE

M12 Flat washer

M12 Flat washer

MAINTENANCE SERVICE

TSB Revision

GENERAL

00-78

18. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS)

M1001003400488

Inspection of brake hoses should be included in all brake ser-
vice operations.
The hoses should be checked for:
1. Incorrect length, severe surface cracking, pulling, scuffing or

worn spots. (If the fabric casing of the hoses is exposed by
cracks or abrasion in the rubber hose cover, the hoses
should be replaced. Eventual deterioration of the hose and
possible bursting failure may occur).

2. Incorrect installation, twisting or interference with wheel, tire

or chassis.

19. BALL JOINT AND STEERING LINKAGE
SEALS (INSPECT FOR GREASE LEAKS AND
DAMAGE)

M1001003500496

1. These components, which are permanently lubricated at the

factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
contamination.

2. Inspect the dust cover and boots for proper sealing, leakage

and damage, and replace them if defective.

20. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE)

M1001003600493

1. These components, which are permanently lubricated at the

factory, do not require periodic lubrication. Damaged seals
and boots should be replaced to prevent leakage or grease
contamination.

2. Inspect the dust cover and boots for proper sealing, leakage

and damage. Replace them if defective.

21. SUSPENSION SYSTEM (INSPECT FOR
LOOSENESS AND DAMAGE)

M1001009600219

Visually inspect the front/rear suspension components for dete-
rioration and damage. Re-tighten the front/rear suspension
components retaining bolts to specified torque.

AC610304AB

Brake hose

AC100948

Boot

Dust
cover

AC

AC000109 AC

Boots