Mitsubishi Outlander: Front Disc Brake Assembly

REMOVAL AND INSTALLATION

Pre-removal operation

• Brake Fluid Draining

Post-installation operation

• Brake Fluid Refilling and Air Bleeding
• Brake Disk Runout Inspection/Correction

Removal steps

1. Brake hose (brake caliper side) connection
2. Gasket
3. Brake caliper assembly
4. Front brake disk
5. Clip
6. Brake pipe connection
7. Brake hose

INSTALLATION SERVICE POINTS

BRAKE HOSE INSTALLATION

1. Pass the brake hose through the hole in the body-side bracket.

2. Install the brake hose to the brake caliper.

3. Install the brake hose at the two fixing points.

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.

INSPECTION

BRAKE DISC CHECK

• Disc wear
• Disc run-out

DISASSEMBLY AND ASSEMBLY

Disassembly steps

1. Bleeder cap
2. Bleeder
3. Guide pin
4. Lock pin
5. Bushing
6. Caliper support (including brake pad assembly, clip, and shim)
7. Shim
8. Brake pad assembly
9. Clip
10. Pin boot
11. Piston boot
12. Piston
13. Piston seal
14. Caliper body

LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS

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 materials.

Blow compressed air through the brake hose installation area to remove the piston and piston boot.

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

• 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.

BRAKE PAD WEAR CHECK

WARNING

• Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure 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)

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