Mitsubishi Pajero Pinin. Manual - part 239

BASIC BRAKE SYSTEM – 

Front Disc Brake

35A-24

DISASSEMBLY SERVICE POINTS

A

A

"

PISTON BOOT/PISTON REMOVAL

Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.

Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.

A

B

"

PISTON SEAL REMOVAL

1.

Remove the piston seal with finger tip.

Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.

2.

Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.

Specified brake fluid: DOT3 or DOT4

INSPECTION

D

Check the cylinder for wear, damage or rust.

D

Check the piston surface for wear, damage or rust.

D

Check the caliper body or sleeve for wear.

D

Check pad for damage or adhesion of grease, check the
backing metal for damage.

PAD WEAR CHECK

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

Standard value: 10 mm

Limit: 2.0 mm

Caution
1.

Always replace the brake pads as an axle set.

2.

If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.

BASIC BRAKE SYSTEM – 

Rear Disc Brake

35A-25

REAR DISC BRAKE

REMOVAL AND INSTALLATION

Pre-removal Operation

D

Brake Fluid Draining

Post-installation Operation

D

Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-10.)

2

3

55 – 65 Nm

1

15 Nm

Removal steps

1. Brake hose connection

"

A

A

2. Disc brake assembly
3. Brake disc

INSTALLATION SERVICE POINT

"

A

A

DISC BRAKE ASSEMBLY INSTALLATION

1.

In order to measure the brake drag force after pad
installation, use a spring balance to measure the
rotary-sliding resistance of the hub with the pads removed.

2.

Install the caliper support to the backing plate, and then
assemble the pad clip and the pad to the caliper support.

Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.

BASIC BRAKE SYSTEM – 

Rear Disc Brake

35A-26

3.

Clean the piston and insert it into the cylinder with the
special tool.

4.

Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.

5.

Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.

6.

Turn the brake disc forward 10 times.

7.

Use a spring balance to measure the rotary-sliding
resistance of the hub.

8.

Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].

Standard value: 34 N

9.

If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the
guide pin slide smoothly.

MB990520

BASIC BRAKE SYSTEM – 

Rear Disc Brake

35A-27

10

11

12

14

14

1

4

5

6

7

8

9

43 Nm

8 Nm

15

5

DISASSEMBLY AND REASSEMBLY

Clip set

15

15

Brake caliper kit

Pad set

Seal and boots kit

2

3

5

1

10

5

9

8

7

6

13

12

9

3

5

5

7

Grease

Shim set

6

11

3

2

13

15

Disassembly steps

"

A

A

1. Guide pin

"

A

A

2. Lock pin
3. Bushing
4. Caliper support (pad, clip, shim)
5. Pin boot
6. Boot ring

A

A

"

7. Piston boot

A

A

"

8. Piston

A

B

"

9. Piston seal

10. Caliper body

11. Pad and wear indicator assembly

12. Pad assembly
13. Inner shim
14. Outer shim
15. Clip