Mitsubishi Lancer Evolution IX. Manual - part 491

FRONT DISC BRAKE ASSEMBLY

SERVICE BRAKES

35A-19

FRONT DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351006000526

CAUTION

Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. 
And if there is brake fluid on the caliper, wipe it off quickly.

Pre-removal Operation
• Brake Fluid Draining

Post-installation Operation
• Brake Fluid Supplying and Air Bleeding (Refer to 

P.35A-7

).

AC211991 AB

N

108 ± 10 N·m

2

1

3

30 ± 5 N·m

4

Removal steps 

1. Brake hose connection
2. Gasket

>>

A

<< 3. Brake caliper assembly

4. Brake disc

INSTALLATION SERVICE POINT
>>A<< BRAKE CALIPER ASSEMBLY 
INSTALLATION

1. Find the drag force of the disc brake (Refer to 

P.35A-8

).

Standard value: 69 N or less

2. If that drag force exceeds the standard value, 

disassemble the caliper assembly. Then check 
the piston for contamination or rust, and confirm if 
the piston or the piston seal is deteriorated.

INSPECTION

M1351006100341

BRAKE DISC CHECK
Disc wear (Refer to 

P.35A-11

).

Disc run-out (Refer to 

P.35A-12

).

FRONT DISC BRAKE ASSEMBLY

SERVICE BRAKES

35A-20

DISASSEMBLY AND REASSEMBLY

M1351006200586

CAUTION

Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. 
And if there is brake fluid on the caliper, wipe it off quickly.

AC211994 AB

Brake caliper kit

Pad set

Shim set

Seal and boot repair kit

14 ± 2 N·m

Clip set

N

3

1

1

1

10

10

7

7

7

7

N

9

9

9

9

2

2

2

2

8

8

6

6

6

6

4

1

5

5

3

3

4

4

5

5

Grease: Repair kit grease

Disassembly steps 

1. Pin
2. Pad anti-squeak spring
3. Pad and wear indicator assembly
4. Pad assembly
5. Shim
6. Caliper bleeder

<<

A

>>

7. Piston boot

<<

A

>>

8. Piston

<<

B

>>

9. Piston seal
10. Caliper body

FRONT DISC BRAKE ASSEMBLY

SERVICE BRAKES

35A-21

DISASSEMBLY SERVICE POINTS

CAUTION

Take care not to contact the parts or tools to the 
caliper because the paint of caliper will be 
scratched. And if there is brake fluid on the cali-
per, wipe it off quickly.
When disassembling the disc brakes, disassemble 
both sides (left and right) as a set.

<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION

Do not remove one piston completely before try-
ing to remove the other piston, because it will 
become impossible to remove other pistons.

AC212148

AB

Wood block

Remove the pistons by pumping in air slowly from 
the brake hose connection. Be sure to use a wood 
block and adjust the height of the four pistons so that 
the pistons protrude evenly.

<<B>> PISTON SEAL REMOVAL

CAUTION

To prevent damage to inner cylinder, do not use a 
flat-tipped screwdriver or other tool.
1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with 

alcohol or brake fluid DOT 3 or DOT 4.

INSPECTION

M1351006300431

• Check the cylinder for wear, damage or rust.

• Check the piston surface for wear, damage or 

rust.

• Check the caliper body 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). Failure to do so will result in 
uneven braking, which may cause unrelia-
ble brake operation.

•

ACX00690

If there is significant difference in the 
thickness of the pads on the left and right 
sides, check the moving parts.

Measure thickness at the thinnest, most worn area of 
the pad. Replace the pad assembly if pad thickness 
is less than the limit value.

Standard value: 10.0 mm
Minimum limit: 2.0 mm

REAR DISC BRAKE ASSEMBLY

SERVICE BRAKES

35A-22

REAR DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351007000411

CAUTION

Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. 
And if there is brake fluid on the caliper, wipe it off quickly.

Pre-removal Operation
• Brake Fluid Draining

Post-installation Operation
• Brake Fluid Filling and Air Bleeding (Refer to 

P.35A-7

).

AC403344AB

N

15 ± 2 N·m

2

1

3

54 ± 5 N·m

4

Removal steps 

1. Brake hose connection
2. Gasket

>>

A

<< 3. Brake caliper assembly

4. Brake disc

INSTALLATION SERVICE POINT
>>A<< BRAKE CALIPER ASSEMBLY 
INSTALLATION

1. Find the drag force of the disc brake (Refer to 

P.35A-8

).

Standard value: 69 N or less

2. If that drag force exceeds the standard value, 

disassemble the caliper assembly. Then check 
the piston for contamination or rust, and confirm if 
the piston or the piston seal is deteriorated.

INSPECTION

M1351007100300

BRAKE DISC CHECK

Disc wear: Refer to 

P.35A-11

.

Disc run-out: Refer to 

P.35A-12

.