Mitsubishi Outlander (2003+). Manual - part 262

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE SYSTEM

35A-19

FRONT DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351006000452

INSTALLATION SERVICE POINTS

>>A<< FRONT BRAKE ASSEMBLY 
INSTALLATION

1. In order to measure the brake drag torque, 

measure the hub torque with the pads removed by 
the following procedure.
(1) Use a spring balance to measure the hub 

torque in the forward direction.

(2) Record hub torque with pads removed.

CAUTION

Do not let any oil, grease or other contamination 
get onto the friction surfaces of the pads and 
brake discs.
2. After re-installing the caliper support to the 

knuckle, install the pad clips and the pads to the 
caliper support.

3. Clean the piston and insert into cylinder with 

special tool disc brake piston expander 
(MB990520).

4. Be careful that the piston boot does not become 

caught, when lowering the caliper assembly and 
installing the guide pin bolt.

AC301353AB

N

100 ± 10 N·m

2

1

3

30 ± 5 N·m

4

Removal steps

•

Brake fluid draining

1. Brake hose connection
2. Brake fluid line gasket
3. Front brake assembly
4. Front brake disc

Installation steps

4. Front brake disc

>>A<<

3. Front brake assembly
2. Brake fluid line gasket
1. Brake hose connection

•

Brake fluid supplying and air bleeding 
(Refer to 

P.35A-7

).

>>B<<

•

Brake drag force check

AC000906AF

Spring balance

AC301354

MB990520

AB

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE SYSTEM

35A-20

>>B<< BRAKE DRAG FORCE CHECK
1. Check the brake drag force as follows.

(1) Start the engine and hold the brake pedal 

down for 5 seconds. (Pedal depression force: 
approximately 200 N)

(2) Stop the engine.
(3) Turn the brake disc forward 10 times.

(4) Use a spring balance 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: 68 N or less

2. If the brake drag force 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

M1351006100277

BRAKE DISC CHECK
Disc wear (Refer to 

P.35A-10

).

Disc run-out (Refer to 

P.35A-10

).

AC000908

Spring balance

AE

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE SYSTEM

35A-21

DISASSEMBLY AND REASSEMBLY

M1351006200423

AC202238

AD

10

9

11

1

3

14

13

12

14

5

1

2

3

4

13

11

12

5

11

7

6

9

7

74 ± 10 N·m

7.9 ± 0.9 N·m

10

2

6

74 ± 10 N·m

5

9

8

8

7

6

14

14

4

5

5

9

8 7

6

8

9

7

6

7

2

5

Caliper kit

Pad set

Shim set

Caliper seal kit

Clip set

Grease

Disassembly steps

1. Lock pin
2. Bushing
3. Guide pin
4. Caliper support (including pad, clip, 

and shim)

5. Pin boot
6. Boot ring

<<A>>

7. Piston boot

<<A>>

8. Piston

<<B>>

9. Piston seal
10. Caliper body
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim
14. Clip

Disassembly steps (Continued)

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE SYSTEM

35A-22

LUBRICATION POINTS

AC202239

Piston seal

Brake fluid: DOT 3 or DOT 4

AD

Grease: Repair kit grease

The piston seal inside the caliper seal 
kit is coated with a special grease.
Do not wipe this grease off.

   !   CAUTION

Grease: Repair kit grease

Grease: Repair kit grease