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Mitsubishi Montero (1998+). Manual - part 59

WHEEL CYLINDERS

Removal & Installation

Raise and support vehicle. Remove rear brake drum and shoes.

See REAR BRAKE DRUM & SHOES. Remove wheel cylinder and seal assembly.

To install, reverse removal procedure. Bleed brakes. See

BLEEDING BRAKE SYSTEM.

MASTER CYLINDER

Removal

Drain brake fluid from master cylinder. Remove sensor

connector (if equipped). Disconnect brake lines from master cylinder,

and install plugs to prevent brake fluid spillage. Remove master

cylinder from booster and separate reservoirs from housing (if

necessary).

Installation

To install, reverse removal procedure. Before installation,

check and adjust clearance between back of master cylinder piston and

power brake push rod. See MASTER CYLINDER PUSH ROD under ADJUSTMENTS.

After installation, adjust pedal height. See BRAKE PEDAL HEIGHT & FREE

PLAY under ADJUSTMENTS. Bleed brake system.

POWER BRAKE BOOSTER

Removal

Remove brake master cylinder. See MASTER CYLINDER. Disconnect

vacuum hose from power brake booster. Disconnect clevis pin attaching

brake pedal to power brake booster push rod. From inside vehicle,

remove 4 nuts attaching power brake booster to firewall. Remove power

brake booster.

Installation

To install, reverse removal procedure. Install master

cylinder. Bleed brake system if necessary.

POWER BRAKE BOOSTER CHECK VALVE

NOTE: To test check valve before removal, see POWER BRAKE BOOSTER

under TESTING.

Removal & Installation

Remove vacuum hose with check valve from power brake booster.

Loosen hose clamp(s) and remove check valve from hose on Mirage and

Summit. On all models, coat end(s) of check valve with sealant before

installation. Install valve with arrow (identification mark) pointing

toward intake manifold. Install and secure hose clamp(s).

REAR AXLE BEARINGS & OIL SEAL

Removal (Montero & Montero Sport)

1) With disc or drum removed, disconnect brake line from

caliper or wheel cylinder. Disconnect parking brake cable end, and

remove cable attaching bolts. Remove brake backing plate, bearing case

and axle shaft as an assembly. If axle shaft binds, use slide hammer

and puller to remove.

2) Remove shims, "O" ring and snap ring. Retain shims for

installation. Secure axle shaft assembly in a vise, and remove one

retainer bolt from backing plate. Push bearing case completely to side

of dust cover. Place adhesive tape around edge of bearing case at

retainer bolt hole to prevent damage.

CAUTION: DO NOT damage bearing case or axle shaft when grinding or

chiseling retainer ring.

3) Secure axle shaft, and grind retainer ring until retainer

ring wall thickness is 0.04-0.06" (1.0-1.5 mm) on axle shaft side and

0.08" (2.0 mm) on bearing side (FIRST CUT). See Fig. 9.

4) Change angle of grind, and remove remaining 0.08" (2.0 mm)

of retainer ring wall on bearing side (SECOND CUT). Using a chisel,

cut retainer ring. Remove ring. DO NOT damage axle shaft.

5) Install Puller (MB990787-01) to remove bearing case from

axle shaft. Rotate nuts with equal force to remove wheel bearing.

Remove bearing outer race using a hammer and drift. Remove oil seal

from axle housing using a slide hammer and hook.

Fig. 12: Grinding Bearing Retainer Ring (Montero & Montero Sport)

Courtesy of Mitsubishi Motor Sales of America.

Installation

1) Apply Multipurpose Grease (SAE J310) to oil seal, oil seal

cavity and contact surfaces. Install oil seal using seal driver. Press

new oil seal into bearing case until it is flush with face of bearing

case. Install backing plate and bearing case.

2) Apply grease to external surfaces of bearing outer race.

Press bearing outer race into bearing case. Install rear brake

assembly and bearing case. Pack bearing case and axle threads with

grease. Install new retainer ring and snap ring.

3) Using a feeler gauge, measure clearance between snap ring

and new retainer ring. Clearance should be less than 0.0065" (0.165

mm). If clearance exceeds specification, install a new selective snap

ring to bring clearance to specification. See SNAP RING THICKNESS

SPECIFICATION table.

SNAP RING THICKNESS SPECIFICATION

Thickness: In. (mm) Color

0.060 (1.52) ................................................... Red

0.067 (1.70) ................................................ Purple

0.073 (1.85) .................................................. Blue

0.079 (2.01) ................................................ Yellow

0.085 (2.16) ............................................... Neutral

4) Check condition of oil seal and replace as necessary.

Install axle shaft assembly into axle housing. Tighten bearing

retainer bolts to 65 ft. lbs (15 N.m.). To complete installation,

reverse removal procedure.

REAR AXLE HUB BEARINGS

NOTE: Rear hub bearings are not serviceable on FWD models.

Removal & Installation (FWD Models)

1) Raise and support vehicle. Remove wheels. Remove wheel

speed sensor (if equipped). On models with drum brakes, remove brake

drum and shoes. See REAR BRAKE DRUM & SHOES.

2) On models with disc brakes, remove caliper and rotor. On

all models, remove hub bolts or spindle nut and hub assembly. To

install, reverse removal procedure. Tighten hub bolts or spindle nut

to specification. See HUB TIGHTENING TORQUE table. Rotate brake drum

or disc to ensure free movement.

NOTE: Rear hub bearings are not serviceable on Eclipse AWD models.

Removal & Installation (Eclipse AWD)

1) Raise and support vehicle. Remove wheels. Remove wheel

speed sensor (if equipped). On models with drum brakes, remove brake

drum and shoes. See REAR BRAKE DRUM & SHOES.

2) On models with disc brakes, remove caliper and rotor. On

all models, remove axle nut. Remove 4 hub bolts and hub assembly. To

install, reverse removal procedure. Tighten hub bolts to

specification. See HUB TIGHTENING TORQUE table. Rotate brake drum or

disc to ensure free movement.

HUB TIGHTENING TORQUE

Application Ft. Lbs. (N.m)

Hub Mounting Bolts ................................... 54-65 (74-85)

Spindle Nut

Mirage ................................................. 127 (172)

3000GT FWD ............................................. 170 (230)

Removal & Installation (3000GT AWD Models)

1) Raise and support vehicle. Remove wheels. Remove wheel

speed sensor (if equipped). Remove caliper and rotor.

2) Remove 4 bolts and separate rear drive axle from hub

companion flange. Using Yoke Holder (MB990767), hold rear axle hub and

remove axle nut at companion flange.

3) Using slide hammer and Hub Adapter (MB991354), remove axle

shaft from knuckle. Place axle in hydraulic press. Using an

appropriate bearing splitter, remove ABS rotor (if equipped) and outer

axle bearing.

4) Remove inner bearing and seal from axle. Using Bearing

Installer Handle (MB990938) and Adapter (MB990931), install bearing

and axle seal.

5) Using Installer (MB990799), install dust shield onto axle

shaft. Using hydraulic press, install outer axle bearing onto axle

shaft so seal lip is facing towards axle shaft. Press on wheel speed

sensor rotor (if equipped) with groove on speed sensor rotor is facing

towards axle shaft flange.

6) Install axle shaft assembly into knuckle and tighten axle

nut to 188-217 ft. lbs. (260-300 N.m.). To complete installation,

reverse removal procedure. Tighten bolts to specification.

OVERHAUL

NOTE: For exploded views of calipers, see Figs. 13 through 17. For

exploded view of master cylinder, see Fig. 18.

Fig. 13: Exploded View Of Single Piston Caliper Assembly (Except

Montero Sport)

Courtesy of Mitsubishi Motor Sales of America.

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