Mitsubishi Outlander XL. Manual - part 608

REAR DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M13501000070USA0000010000

Pre-removal operation
Brake fluid draining

Post-installation operation
Brake fluid refilling and air bleeding (Refer to P.35A-18).

ZC601849AA00

60 ± 5 N·m 
45 ± 3 ft-lb

1

4

2

5

16 ± 3 N·m 
12 ± 2 ft-lb

16 ± 3 N·m 
12 ± 2 ft-lb

3

6

Removal steps

1.

Clip

2.

Connection  between  brake  pipe  and
brake hose

3.

Connection  between  brake  hose  and
rear brake caliper assembly

Removal steps

4.

Brake hose

>>A<<

5.

Rear brake caliper assembly

6.

Rear brake disc

 

INSTALLATION SERVICE POINTS

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

ZC602447AA00

1.

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

BASIC BRAKE SYSTEM

35A-33

REAR DISC BRAKE ASSEMBLY

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.

Install the caliper support to the backing plate assembly, and
assemble the pad clip and pad to the caliper support.

4.

Lower the caliper assembly with care not to catch the piston
boot, and tighten the lock pin to the specified torque.

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

5.

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

6.

Turn the brake disc 10 times in the forward direction.

ZC602448AA00

7.

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

8.

Obtain  the  disc  brake  drag  force  (difference  between
measured values of item 1 and item 7).

Standard value: 68 N (15.3 pounds) or less

9.

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.

35A-34

BASIC BRAKE SYSTEM

REAR DISC BRAKE ASSEMBLY

DISASSEMBLY AND ASSEMBLY

M13501000072USA0000010000

ZC601943AA00

7

6

Repair kit grease

9

Shim kit

Seal & boots kit

Brake caliper kit

Clip set

Pad set

1 : Left side 
2 : Right side

3

3

5

10

10

4

5

8

44 ± 5 N·m 
32 ± 4 ft-lb

13

12

14

11

15

7.9 ± 0.9 N·m 
70 ± 8 in-lb

2

8

9

6

7

7

15

10

11

13

14

4

4

1

10

10

10

13

14

12

11

5

3

3

5

Disassembly steps

1.

Pad/wear indicator assembly (inner)

2.

Pad assembly (inner)

3.

Clip

4.

Pad/clip assembly (outer)

5.

Shim

6.

Lock pin

7.

Bushing

8.

Guide pin

Disassembly steps

9.

Caliper support

10. Pin boot
11. Boot ring

<<A>>

12. Piston

<<B>>

13. Piston seal

<<A>>

14. Piston boot
15. Caliper body

 

BASIC BRAKE SYSTEM

35A-35

REAR DISC BRAKE ASSEMBLY

LUBRICATION POINTS

ZC6010760000

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

35A-36

BASIC BRAKE SYSTEM

REAR DISC BRAKE ASSEMBLY