Mitsubishi Montero (2004+). Manual - part 1036

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-143

BUZZER CHECK

M1351016200015

Check that the buzzer sounds when a battery is connected to 
the buzzer as shown in the illustration.

FRONT DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351006000269

Required Special Tool:

• MB990520: Disc Brake Piston Expander

ACX00680AB

Pre-removal Operation
• Brake Fluid Draining

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

P.35A-125

.)

ACX00681AB

113 ±

 9 N

•

m

83 ±

 7 ft-lb

30 ±

 4 N

•

m

22 ±

 3 ft-lb

2

2

1

3

4

N

N

REMOVAL STEPS

1. BRAKE HOSE CONNECTION
2. GASKET

>>A<<

3. DISC BRAKE ASSEMBLY
4. BRAKE DISC

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-144

INSTALLATION SERVICE POINT

.

>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. To check the brake drag force after mounting the pad, 

measure the hub torque in the advancing direction using a 
spring scale with the pad is removed.

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 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 

MB990520.

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

when lowering the caliper assembly and installing the guide 
pin.

5. Check the 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 pound)]

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

6. 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

M1351006100181

Brake Disc Check

• Disc wear (Refer to 

P.35A-133

.)

• Disc run-out (Refer to 

P.35A-134

.)

ACX00683

ACX00684AB

MB990520

ACX00685

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-145

DISASSEMBLY AND ASSEMBLY

M1351006200285

ACX00686AB

89 ± 4 N

•

m

66 ± 3 ft-lb

89 ± 4 N

•

m

66 ± 3 ft-lb

7.4 ± 1.4 N

•

m

65 ± 13 in-lb

2

2

1

1

9

9

13

13

13

13

13

13

10

11

12

12

4

4

4

8

8

8

7

7

6

6

6

5

5

5

3

3

CLIP KIT

10

11

BRAKE CALIPER KIT

PAD SET

SHIM KIT

SEAL AND BOOT KIT

N

N

N

N

DISASSEMBLY STEPS

1. GUIDE PIN LOCK BOLT
2. GUIDE PIN
3. CALIPER SUPPORT, PAD, CLIP AND 

SHIM ASSEMBLY

4. BOOT
5. BUSHING

<<A>>

6. PISTON BOOT

<<A>>

7. PISTON

<<B>>

8. PISTON SEAL
9. CALIPER BODY
10. PAD AND WEAR INDICATOR 

ASSEMBLY

11. PAD ASSEMBLY
12. SHIM
13. CLIP

DISASSEMBLY STEPS (Continued)

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-146

LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS

CAUTION

When disassembling the front disc brakes, disassemble 
both sides (left and right wheels) as a set.

.

ACX00687AC

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

BRAKE FLUID: DOT3 OR DOT4

THE PISTON SEAL INSIDE THE
SEAL AND BOOT KIT IS COATED
WITH SPECIAL GREASE DO NOT 
WIPE THIS GREASE OFF.

GREASE: REPAIR KIT GREASE

PISTON
SEAL

CAUTION