Mitsubishi L200. Manual - part 417

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE

35A-32

<<A>> PISTON BOOT/PISTON REMOVAL

ACX00697

CAUTION

Blow air little by little to remove the piston. The 
piston will rush out if a force of air is applied sud-
denly.
Place a piece of wood, etc. against the caliper body 
as shown. Blow compressed air through the brake 
hose 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.

ACX00689

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

alcohol or brake fluid DOT 3 or DOT 4.

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE

35A-33

DISASSEMBLY AND REASSEMBLY <2WD 
(High rider), 4WD>

M1351006202087

AC805542AB

27 ± 4 N·m

7.9 ± 0.9 N·m

N

5

7

12

14

6

N

11

6

13

12

6

4

14

Grease

3

1

2

5

6

N

4

10

11

8

8

N

15

3

1

2

5

13

14

15

5

12

6

6

9

10

10

7

11

11

9

9

11

8

9

9

9

9

9

7

7

11

<Right side>

<Left side>

<Right side>

<Left side>

7

7

<Right side>

<Left side>

Front brake clip set

Front brake shim set

Front brake pad set

Front brake caliper seal kit

Front brake caliper kit

<Standard brake pads>

<Right side>

<Left side>

<Standard brake pads>

<Right side>

<Left side>

<Low steel brake pads>

<Low steel brake pads>

<Standard brake pads>

<Low steel brake pads>

Disassembly steps 

1. Bleeder cap
2. Bleeder
3. Pin bolt
4. Caliper support (including pad, clip, 

and shim)

5. Pin
6. Pin boot
7. Brake pad assembly
8. V spring
9. Shim
10. Shim cover
11. Clip

<<

A

>>

12. Piston boot

<<

A

>>

13. Piston

<<

B

>>

14. Piston seal
15. Caliper body

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE

35A-34

NOTE: 

.

•

The brake pad assembly with wear indicator is 
installed only to the inner side of the brake disc of 
the left-side brake at factory.

•

As for the accessory pad set, the brake pad with 
wear indicator has been established to the inner 
side of the brake disc on both right side brake 
and left side brake. <Vehicles with low steel 
brake pads>

•

Install the brake pad assembly (with wear indica-
tor) to the inner side of the brake disc, making 
sure that the wear indicator is located on the bot-
tom.

FRONT DISC BRAKE ASSEMBLY

BASIC BRAKE

35A-35

LUBRICATION POINTS

AC805311

Piston seal

Brake fluid: DOT 3 or DOT 4

AB

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

   !   CAUTION

Grease: Repair kit grease (Colour: 
               Translucent red), Niglube RX-2 
               or equivalent

Grease: Repair kit grease (Colour: 
               Translucent red), Niglube RX-2 
               or equivalent

Grease: Repair kit grease

DISASSEMBLY SERVICE POINTS

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