Mitsubishi Outlander XL. Manual - part 607

ZC601061

A

View A

Correct

Bracket

Brake hose

0000

Wrong

4.

Twist the brake hose toward the lesser torsion between the
brake hose and body-side bracket as shown in the figure, and
fix it to the body-side bracket with a clip.

 

>>B<< BRAKE CALIPER ASSEMBLY INSTALLATION
Measure the brake drag force in the following procedure:

ZC6010620000

1.

Using a spring scale, measure the hub sliding torque in the
forward direction.

ZC601063

MB990520

0000

Keep  grease  or  other  soiling  off  the  pad  and  brake  disc
friction surfaces.

2.

Clean the piston, and press the piston into the cylinder using
the piston expander (Special tool: MB990520).

3.

Assemble  the  pad  clip  and  pad  to  the  caliper  support,  and
tighten the guide pin to the specified torque.

Tightening torque: 44 ± 5 N·m (32 ± 4 ft-lb)

4.

Start the engine, and depress the brake pedal forcibly two or
three times. Then, stop the engine.

5.

Turn the brake disc 10 times in the forward direction.

ZC601064 0000

6.

Using a spring scale, measure the hub sliding torque in the
forward direction.

7.

Obtain  the  disc  brake  drag  force  (difference  between
measured values of item 1 and item 6).

Standard value: 68 N (15.3 pounds) or less

8.

If  the  brake  drag  force  exceeds  the  standard  value,
disassemble the piston to check for fouling/rust on the piston
sliding  section  and  piston/seal  deterioration,  and  confirm
whether the slide pin slides properly.

BASIC BRAKE SYSTEM

35A-29

FRONT DISC BRAKE ASSEMBLY

DISASSEMBLY AND ASSEMBLY

M13501000062USA0000010000

ZC601942AA00

2

1

44 ± 5 N·m 
32 ± 4 ft-lb

44 ± 5 N·m 
32 ± 4 ft-lb

7.9 ± 0.9 N·m 
70 ± 8 in-lb

7

7

4

6

9

8

13

8

12

3

11

10

5

4

2

1

8

9

8

10

12

9

8

8

5

6

5

6

13

11

11

12

3

Clip set

Shim kit

Pad set

Repair kit grease

Seal and boot kit

Brake caliper kit

4

4

7

7

Disassembly steps

1.

Lock pin

2.

Guide pin

3.

Caliper support
(including pad, clip, and shim)

4.

Shim

5.

Pad & wear indicator assembly

6.

Pad assembly

7.

Clip

Disassembly steps

8.

Pin boot

9.

Bushing

<<A>>

10. Piston

<<B>>

11. Piston seal

<<A>>

12. Piston boot
13. Caliper body

 

35A-30

BASIC BRAKE SYSTEM

FRONT DISC BRAKE ASSEMBLY

LUBRICATION POINTS

ZC601068 0000

Brake fluid: DOT 3 or DOT 4

Grease: Repair kit grease

Grease: Repair kit grease

Grease: Repair kit grease

The piston seal inside the caliper seal  
kit is coated with a special grease. 
Do not wipe this grease off.

CAUTIO N

Piston seal

DISASSEMBLY SERVICE POINT

<<A>> PISTON BOOT/PISTON REMOVAL

Blow air gradually to remove the pistons. The pistons will
rush out if a force of air is applied suddenly.

BASIC BRAKE SYSTEM

35A-31

FRONT DISC BRAKE ASSEMBLY

ACX00697

ZC5012520000

Cover the caliper body outer side with a cloth or similar materials.
Blow compressed air through the brake hose installation area to
remove the piston and piston boot.

<<B>> PISTON SEAL REMOVAL

ACX00689

ZC5012530000

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

FRONT DISC BRAKE ASSEMBLY INSPECTION

M13501000061USA0000010000

PAD WEAR INSPECTION

｠

When replacing, replace both pads (right and left) as a set.

｠

If there is a significant difference in thickness between the
pads at right and left, check the sliding area of the brake
caliper.

ZC601069 0000

Measure the pad thickness at the most worn area. If the pad
thickness is less than the limit value, replace the pad.

Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

35A-32

BASIC BRAKE SYSTEM

FRONT DISC BRAKE ASSEMBLY