Mitsubishi Evolution X. Manual - part 823

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-19

3. Remove the following parts from the brake caliper assembly.

(1) Shim
(2) Brake pad assembly

CAUTION

Keep grease or other soiling off the pad and brake disk 
friction surfaces.

AC706163AB

MB990520

Piston

Caliper 
body

4. Clean the piston, then press the piston into the cylinder 

using the piston expander (Special tool: MB990520).

AC710738AB

<Front>

<Rear>

Grease: Repair kit grease, Molykote AS880N 
or equivalent 

AC710739AB

<Rear>

Grease: Repair kit grease, Molykote 7439 
or equivalent

<Front>

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-20

5. Apply grease to the pad as shown in the figure.

Grease:

Between pad and shim: Repair kit grease, Molykote 

AS880N or equivalent

Shoulder section: Repair kit grease, Molykote 7439 

or equivalent

6. Install the shim to the brake pad assembly. Then, install the 

brake pad assembly to the brake caliper assembly so that 
the direction of shim arrow points to the same direction as 
the brake disk rotation direction of when the vehicle travels 
forward.
NOTE: Install the brake pad assembly (with wear indicator) 
to outside the vehicle.

7. Install the cross spring to the brake caliper assembly.

AC211990AC

Cross 
spring

Pin

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-21

8. While pressing the cross spring by hand, install the pin to 

the brake caliper assembly.

DISK BRAKE ROTOR CHECK

M1351002900710

CAUTION

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

Inspection item

Remark

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.

Inset or warping (flatness)

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

.

BRAKE DISK THICKNESS CHECK

ACX00668 AB

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).

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-22

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.

•

AC006226 AE

M12 Flat washer

M12 Flat washer

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.

ACX00669AB

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.