Mitsubishi Outlander GS45X. Manual - part 1552

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE

35A-37

DISASSEMBLY SERVICE POINTS

.

<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION

Blow air gradually to remove the pistons. The pistons will 
rush out if a force of air is applied suddenly.
Cover the caliper body outer side with a cloth or similar materi-
als. Blow compressed air through the brake hose installation 
area to remove the piston and piston boot.

.

<<B>> PISTON SEAL REMOVAL

CAUTION

Do not use a flat-tipped screwdriver to remove the piston 
seal. This may damage the inner side of the cylinder.

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol 

or specified brake fluid.

Brake fluid: DOT3 or DOT4

INSPECTION

M1351015000579

• Check the cylinder for wear, damage or rust.

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

• Check the caliper body for wear.

• Check the pad for damage or adhesion of grease, check the 

backing metal for damage.

.

ACX00697

ACX00689

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE

35A-38

BRAKE 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 
moving parts.

Measure thickness at the thinnest, 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)
Limit: 2.0 mm (0.08 inch)

AC506397

REAR DISC BRAKE ASSEMBLY

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BASIC BRAKE

35A-39

REAR DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION <2.4L ENGINE: 5 PERSONS SEAT>

M1351007001027

Pre-removal operation
Brake Fluid Draining

Post-installation operation
• Brake Fluid Refilling and Air Bleeding (Refer to 

P.35A-20

).

• Brake Disk Runout Inspection/Correction (Refer to 

P.35A-24

).

• Parking Brake Lining Seating Procedure (Refer to 

GROUP 36, Parking Brake Lining Seating Procedure 

P.36-10

).

AC610145AC

3

4

6

5

55 ± 5 N·m
41 ± 3 ft-lb

16 ± 3 N·m
12 ± 2 ft-lb

1

2

16 ± 3 N·m
12 ± 2 ft-lb

Removal steps 

1.

Brake tube (brake hose side) 
connection

2.

Clip

3.

Brake hose

4.

Rear brake caliper assembly

5.

Rear brake disk

6.

Plug

Removal steps (Continued)

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE

35A-40

REMOVAL AND INSTALLATION <2.4L ENGINE: 7 PERSONS SEAT, 3.0L ENGINE>

M1351007001038

INSPECTION

M1351007100399

.

BRAKE DISC CHECK

• Disc wear (Refer to 

P.35A-24

).

• Disc run-out (Refer to 

P.35A-24

).

Pre-removal operation
Brake Fluid Draining

Post-installation operation
• Brake Fluid Refilling and Air Bleeding (Refer to 

P.35A-20

).

• Brake Disk Runout Inspection/Correction (Refer to 

P.35A-24

).

• Parking Brake Lining Seating Procedure (Refer to 

GROUP 36, Parking Brake Lining Seating Procedure 

P.36-10

).

AC800505

1

4

6

2

3

5

AB

16 ± 3 N·m
12 ± 2 ft-lb

16 ± 3 N·m
12 ± 2 ft-lb

58 ± 7 N·m
43 ± 5 ft-lb

Removal steps 

1.

Brake tube (brake hose side) 
connection

2.

Clip

3.

Brake hose

4.

Rear brake caliper assembly

5.

Rear brake disk

6.

Plug

Removal steps (Continued)