Mitsubishi Montero (2002-2004). Manual - part 1030

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-145

INSPECTION

M1351006300248

• Check the cylinder for wear, damage or rust.

• Check the piston surface for wear, damage or rust.

• Check the caliper body or sleeve 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). Fail-
ure to do so will result in uneven braking, which 
may cause unreliable brake operation.

•

If there is significant difference in the thickness of 
the pads on the left and right sides, check the slid-
ing condition of the piston, lock pin and guide pin.

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

Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

ACX00690

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-146

REAR DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351007000187

Required Special Tool:

• MB990520: Disc Brake Piston Expander

INSTALLATION SERVICE POINT

.

>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure brake drag torque after pad installation, 

measure hub torque with the pads removed.
Use a spring scale to measure hub torque in the direction 
shown. Record the value.

CAUTION

Do not allow any oil, grease or other contamination to con-
tact the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support, install the pad clips 

and pads to the caliper support.

Pre-removal Operation
• Brake Fluid Draining

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

P.35A-

122

.)

AC204328

AB

100 ± 10 N

•

m

74± 7 ft-lb

30 ± 4 N

•

m

22 ± 3 ft-lb

1

2

3

4

N

REMOVAL STEPS

1. BRAKE HOSE CONNECTION
2. GASKET

>>A<<

3. DISC BRAKE ASSEMBLY
4. BRAKE DISC

ACX00692

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-147

3. Clean the piston, and insert it into the cylinder with special 

tool MB990520.

4. Be careful that the piston boot does not become caught 

when lowering the caliper assembly and installing the guide 
pin.

5. Check brake drag force as follows:

(1) Start the engine and hold the brake pedal down for five 

seconds. [Pedal depression force: approximately 196 N 
(44 pounds)]

(2) Stop the engine.
(3) Turn the brake disc forward ten times.
(4) Use a spring scale 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: 55 N (12 pounds)

6. If the drag torque 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

M1351007100184

Brake Disc Check

• Disc wear (Refer to 

P.35A-130

.)

• Disc run-out (Refer to 

P.35A-130

.)

ACX00693AB

MB990520

ACX00694

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-148

DISASSEMBLY AND ASSEMBLY

M1351007200181

AC204380AB

44 ± 5 N

•

m

33 ± 3 ft-lb

1

1

17

17

7.9 ± 0.9 N

•

m

70 ± 8 in-lb

12

12

12

12

9

9

10

10

10

12

12

16

16

16

15

15

14

14

14

13

13

13

6

6

6

6

6

6

2

5

5

5

4

4

4

3

3

3

11

11

CLIP SET

BRAKE CALIPER KIT

PAD SET

SHIM SET

SEAL AND BOOTS KIT

N

N

N

N

8

7

8

7

8

7

DISASSEMBLY STEPS

>>A<<

1. GUIDE PIN
2. PAD AND CLIP ASSEMBLY AND SHIM
3. SHIM
4. PAD AND CLIP ASSEMBLY
5. PAD ASSEMBLY
6. PAD CLIP
7. SHIM B
8. SHIM A

>>A<<

9. LOCK PIN

10. BUSHING
11. CALIPER SUPPORT
12. PIN BOOT
13. BOOT RING

<<A>>

14. PISTON BOOT

<<A>>

15. PISTON

<<B>>

16. PISTON SEAL
17. CALIPER BODY

DISASSEMBLY STEPS (Continued)