Mitsubishi Galant (2004+). Manual - part 512

DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-35

<<A>> CALIPER PISTON/PISTON BOOT REMOVAL

CAUTION

Blow air little by little to remove the piston. The piston will 
pop 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 the 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 

brake fluid DOT 3 or DOT 4.

AC204331

ACX00689

DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-36

DISASSEMBLY AND ASSEMBLY <REAR>

M1351008200076

AC308038

1

AB

1

PAD SET

2

2

CLIP SET

3

SHIM SET

3

3

3

44 ± 5 N·m
32 ± 4 ft-lb

4

4

4

5

N

6

CALIPER KIT

5

6

1

2

2

3

3

8

7

N

7

N

7

8

N

9

N

10

11

N

12

14

13

7.9 ± 0.9 N·m
70 ± 8 in-lb

14

13

7

7

7

10

9

12

5

CALIPER SEAL KIT

9

10

11

12

DISASSEMBLY STEPS

1. PAD (AND WEAR INDICATOR) 

ASSEMBLY

2. CLIP
3. SHIM

>>A<<

4. REAR BRAKE PIN
5. REAR BRAKE BUSHING
6. CALIPER BODY
7. PIN BOOT

8. CALIPER SUPPORT
9. BOOT RING

<<A>>

10. PISTON BOOT

<<A>>

11. CALIPER PISTON

<<B>>

12. PISTON SEAL
13. REAR BRAKE CAP
14. CALIPER BLEEDER

DISASSEMBLY STEPS (Continued)

DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-37

LUBRICATION POINTS

AC308045AB

PISTON
SEAL

BRAKE FLUID: DOT3 OR DOT4

GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE

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

CAUTION

DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-38

DISASSEMBLY SERVICE POINTS

CAUTION

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

.

<<A>> PISTON BOOT/CALIPER PISTON REMOVAL

CAUTION

Blow air little by little to remove the piston. The piston will 
pop 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.

AC204331

AC204684