Mitsubishi Outlander XL. Manual — part 607
ZC601061
A
View A
Correct
Bracket
Brake hose
0000
Wrong
4.
Twist the brake hose toward the lesser torsion between the
brake hose and body-side bracket as shown in the figure, and
fix it to the body-side bracket with a clip.
>>B<< BRAKE CALIPER ASSEMBLY INSTALLATION
Measure the brake drag force in the following procedure:
ZC6010620000
1.
Using a spring scale, measure the hub sliding torque in the
forward direction.
ZC601063
MB990520
0000
Keep grease or other soiling off the pad and brake disc
friction surfaces.
2.
Clean the piston, and press the piston into the cylinder using
the piston expander (Special tool: MB990520).
3.
Assemble the pad clip and pad to the caliper support, and
tighten the guide pin to the specified torque.
Tightening torque: 44 ± 5 N·m (32 ± 4 ft-lb)
4.
Start the engine, and depress the brake pedal forcibly two or
three times. Then, stop the engine.
5.
Turn the brake disc 10 times in the forward direction.
ZC601064 0000
6.
Using a spring scale, measure the hub sliding torque in the
forward direction.
7.
Obtain the disc brake drag force (difference between
measured values of item 1 and item 6).
Standard value: 68 N (15.3 pounds) or less
8.
If the brake drag force exceeds the standard value,
disassemble the piston to check for fouling/rust on the piston
sliding section and piston/seal deterioration, and confirm
whether the slide pin slides properly.
BASIC BRAKE SYSTEM
35A-29
FRONT DISC BRAKE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
M13501000062USA0000010000
ZC601942AA00
2
1
44 ± 5 N·m
32 ± 4 ft-lb
44 ± 5 N·m
32 ± 4 ft-lb
7.9 ± 0.9 N·m
70 ± 8 in-lb
7
7
4
6
9
8
13
8
12
3
11
10
5
4
2
1
8
9
8
10
12
9
8
8
5
6
5
6
13
11
11
12
3
Clip set
Shim kit
Pad set
Repair kit grease
Seal and boot kit
Brake caliper kit
4
4
7
7
Disassembly steps
1.
Lock pin
2.
Guide pin
3.
Caliper support
(including pad, clip, and shim)
4.
Shim
5.
Pad & wear indicator assembly
6.
Pad assembly
7.
Clip
Disassembly steps
8.
Pin boot
9.
Bushing
<<A>>
10. Piston
<<B>>
11. Piston seal
<<A>>
12. Piston boot
13. Caliper body
35A-30
BASIC BRAKE SYSTEM
FRONT DISC BRAKE ASSEMBLY
LUBRICATION POINTS
ZC601068 0000
Brake fluid: DOT 3 or DOT 4
Grease: Repair kit grease
Grease: Repair kit grease
Grease: Repair kit grease
The piston seal inside the caliper seal
kit is coated with a special grease.
Do not wipe this grease off.
CAUTIO N
Piston seal
DISASSEMBLY SERVICE POINT
<<A>> PISTON BOOT/PISTON REMOVAL
Blow air gradually to remove the pistons. The pistons will
rush out if a force of air is applied suddenly.
BASIC BRAKE SYSTEM
35A-31
FRONT DISC BRAKE ASSEMBLY
ACX00697
ZC5012520000
Cover the caliper body outer side with a cloth or similar materials.
Blow compressed air through the brake hose installation area to
remove the piston and piston boot.
<<B>> PISTON SEAL REMOVAL
ACX00689
ZC5012530000
Do not use a flat-tipped screwdriver to remove the piston
seal. This may damage the inner side of the cylinder.
1.
Remove the piston seal with your finger tip.
2.
Clean the piston surface and cylinder inner face with alcohol
or specified brake fluid.
Brake fluid: DOT3 or DOT4
FRONT DISC BRAKE ASSEMBLY INSPECTION
M13501000061USA0000010000
PAD WEAR INSPECTION
⦆
When replacing, replace both pads (right and left) as a set.
⦆
If there is a significant difference in thickness between the
pads at right and left, check the sliding area of the brake
caliper.
ZC601069 0000
Measure the pad thickness at the most worn area. If the pad
thickness is less than the limit value, replace the pad.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
35A-32
BASIC BRAKE SYSTEM
FRONT DISC BRAKE ASSEMBLY
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