Mitsubishi Montero Sport (2004+). Manual - part 777

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-33

DISASSEMBLY AND ASSEMBLY

M1351006200553

AC005052 AB

SHIM KIT

CLIP KIT

SEAL AND BOOTS
REPAIR KIT

PAD SET

BRAKE CALIPER KIT

16

2

1

3

12

11

6

10

9

8

7

6 10

9

8

7

5

6

10 8

7

6

10

8

7

3

GREASE

13

14

13

14

6

10

9

8

7

6

10

9

8

7

2

1

3

12

11

13

14

15

5

16

4

15

16

8 N·m
71 in-lb

74 N·m
55 ft-lb

CALIPER ASSEMBLY 
DISASSEMBLY STEPS

>>A<<

1.

LOCK PIN

>>A<<

2.

GUIDE PIN

3.

BUSHING

4.

CALIPER SUPPORT, PAD, CLIP 
AND SHIM ASSEMBLY

5.

CALIPER SUPPORT

6.

PIN BOOT

7.

BOOT RING

<<A>>

8.

PISTON BOOT

<<A>>

9.

PISTON

<<B>>

10. PISTON SEAL
11. CALIPER BODY
12. BLEEDER SCREW

PAD ASSEMBLY DISASSEMBLY 
STEPS

>>A<<

1. LOCK PIN

>>A<<

2. GUIDE PIN
3. BUSHING
4. CALIPER SUPPORT, PAD, CLIP AND 

SHIM ASSEMBLY

13. PAD AND WEAR INDICATOR 

ASSEMBLY

14. PAD ASSEMBLY
15. OUTER SHIM
16. CLIP

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-34

LUBRICATION POINTS

AC005053 AB

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

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

BRAKE FLUID: DOT3 OR DOT4

9

8

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-35

DISASSEMBLY SERVICE POINTS

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

.

<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION

• When removing the pistons, be sure to use the handle 

of a plastic hammer and adjust the height of the two 
pistons while pumping air slowly in so that the pistons 
protrude evenly.

• Do not remove one piston completely before trying to 

remove the other piston, because it will become impos-
sible to remove the second piston.

Protect the caliper body with a shop towel. Blow compressed 
air through the brake hose to remove the piston boot and pis-
ton.

.

<<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 the piston surface and inner cylinder with alcohol or 

the specified brake fluid DOT3 or DOT4.

ACX00688

AC004463 AB

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-36

ASSEMBLY SERVICE POINT

.

>>A<< LOCK PIN/GUIDE PIN INSTALLATION
Install the lock pin and guide pin to the caliper body as shown in 
the illustration.

INSPECTION

M1351006300419

• 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: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

AC004464 AB

GUIDE PIN

LOCK PIN

ACX00690