Mitsubishi Montero (2004+). Manual - part 1038

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-151

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)

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-152

LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS

CAUTION

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

.

AC205297AB

PISTON
SEAL

BRAKE FLUID: DOT3 OR DOT4

GREASE: REPAIR KIT GREASE

GREASE: BRAKE GREASE J310, NLGI NO.1

GREASE: REPAIR KIT GREASE

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

CAUTION

PAD ASSEMBLY

SHIM A

SHIM B

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-153

<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION

Blow air little by little to remove the piston. The piston will 
rush out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown. 
Blow compressed air through the brake hose connection hole 
to remove the piston boot and piston.

.

<<B>> PISTON SEAL REMOVAL

CAUTION

Do not use a flat-tipped screwdriver or similar tool to 
remove piston seal. These may damage the inner side of 
the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean piston surface and inner cylinder with alcohol or brake 

fluid DOT 3 or DOT 4.

ASSEMBLY SERVICE POINT

.

>>A<< LOCK PIN/GUIDE PIN INSTALLATION
Attach a guide pin at the bleeder nipple side of the caliper body 
and a lock pin at the opposite side.

INSPECTION

M1351007300177

• 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.

AC204331

AC204684

AC204734 AB

GUIDE PIN

LOCK PIN

BLEEDER
NIPPLE

SPECIFICATIONS

TSB Revision

BASIC BRAKE SYSTEM

35A-154

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)

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1351009600260

AC204733

ITEM

SPECIFICATION

Brake line
Brake tube flare nut

15 

± 2 N⋅m (11 ± 2 ft-lb)

Brake pedal
Hydraulic brake booster mounting nut

14 

± 3 N⋅m (124 ± 26 in-lb)

Pedal support member mounting bolt

12 

± 2 N⋅m (107 ± 17 in-lb)

Buzzer
Buzzer mounting nut

5.0 

± 1.0 N⋅m (44 ± 9 in-lb)

Hydraulic brake booster (HBB)
Accumulator

54 

± 5 N⋅m (40 ± 4 ft-lb)

Brake tube flare nut (between master cylinder and pump motor)

15.2 

± 3 N⋅m (11 ± 2 ft-lb)

Clevis nut

25.5 

± 5.1 N⋅m (19 ± 3 ft-lb)

Hydraulic brake booster mounting nut

14 

± 3 N⋅m (124 ± 26 in-lb)

Lead wire screw (hydraulic unit side)

1.7 

± 0.1 N⋅m (15 ± 1 in-lb)

Lead wire screw (pump motor side)

3.0 

± 0.5 N⋅m (26 ± 4 in-lb)

Pump motor bracket mounting bolt

11.8 

± 2.3 N⋅m (104 ± 20 in-lb)

Pump motor mounting bolt

7.8 

± 1.5 N⋅m (69 ± 13 in-lb)

Reservoir assembly mounting screw

1.7 

± 0.3 N⋅m (15 ± 2.6 in-lb)

Front disc brake
Bleeder screw

7.4 

± 1.4 N⋅m (65 ± 13 in-lb)