Mitsubishi Montero (2004+). Manual — part 1037

FRONT DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-147

<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION

• When removing the pistons, be sure to use the handle

of a plastic hammer and adjust the height of the two
pistons while pumping in air slowly so that the pistons
protrude evenly.

• Do not remove one piston completely before trying to

remove the other piston, because it will become impos-
sible to remove the second piston.

• Blow air little by little to remove the piston. The piston

will rush out if a force of air is applied suddenly.

Blow compressed air slowly from the connecting portion of the
brake hose to pull out the piston and the piston boots.

.

<<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 the piston surface and inner cylinder with alcohol

brake fluid DOT 3 or DOT 4.

ACX00688

ACX00689

FRONT DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-148

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-149

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

P.35A-125

.)

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-150

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

P.35A-133

.)

• Disc run-out (Refer to

P.35A-134

.)

ACX00693AB

MB990520

ACX00694