Mitsubishi Colt Ralliart. Manual - part 217

AC403232AB

Stopper groove

Protrusion

ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-14

8. Set as shown so that the protrusion on the pad 

assembly rear face is engaged in the piston 
stopper groove.

9. Install the pad and caliper assembly, and check 

the brake drag force (Refer to 

P.35A-41

).

DISC BRAKE PAD CHECK AND 
REPLACEMENT <RALLIART 
VERSION-R>

M1351002300859

<FRONT>

NOTE: 

AC000879

When new

When worn

AD

Pad

Wear indicator

Brake
disc

The brake pads have indicators that contact the 
brake disc when the brake pad thickness becomes 
1.5 mm, and emit a squealing sound to warn the 
driver.

CAUTION

• Whenever a pad must be replaced, replace 

both LH and RH wheel pads as a set to pre-
vent the vehicle from pulling to one side when 
braking.

• If there is a significant difference in the thick-

ness of the pads on the left and right sides, 
check the sliding condition of the piston and 
slide pins.

AC601033AC

1. Check the brake pad thickness through the caliper 

body check port.
Standard value: 10.5 mm
Minimum limit: 1.5 mm

AC601051AC

2. Remove the bolt. Pivot the caliper assembly and 

hold it with wires.

AC601035AC

1

2

3. Remove the following parts from caliper 

assembly.
(1) Pad assembly <RH> or Pad and wear 

indicator assembly <LH>

(2) Pad assembly

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ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-15

4. In order to measure the brake drag force after pad 

installation, measure the rotary-sliding resistance 
of the hub with the pads removed <Refer to 

P.35A-31

>.

5. Install the pads and caliper assembly, and then 

check the brake drag force <Refer to 

P.35A-31

>.

<Rear>

AC601034AD

1. Visually check the thickness of brake pad from the 

inspection hole of the caliper body.
Standard value: 10.0 mm
Limit value: 1.5 mm

2. When the thickness is lower than the limit value, 

replace the both brake pads (right and left) as a 
set.

3. Disengage the connection between the rear brake 

caliper and rear parking brake cable.

AC601034AE

4. Remove the bolt, and swivel the caliper assembly 

upward to retain with a wire or other similar 
material.

AC601036AC

1

2

5. Remove the following parts from the caliper 

assembly.
(1) Pad assembly <RH> or Pad and wear 

indicator assembly <LH>

(2) Pad assembly

6. In order to measure the brake drag force after pad 

installation, measure the hub sliding torque with 
no pad attached (Refer to 

P.35A-43

).

CAUTION

Keep grease or other fouling off the pad and 
brake disc friction surface. 

AC402607AD

MB996049

7. Clean the piston, and press the piston into the 

cylinder using the special tool, rear disc brake 
piston driver (MB996049).

8. Install the pad and caliper assembly, and check 

the brake drag force (Refer to 

P.35A-43

).

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ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-16

DISC BRAKE ROTOR CHECK

M1351002900594

CAUTION

Disc brakes must be kept within the allowable 
service values in order to maintain normal brake 
operation.
Before turning the brake disc, the following condi-
tions should be checked.

Inspection item

Remark

Scratches, rust, saturated lining materials and wear

• If the vehicle is not driven for a long period of 

time, sections of the discs that are not in contact 
with the pads will become rusty, causing noise 
and shuddering.

• If grooves and scratches resulting from excessive 

disc wear are not removed prior to installing a new 
pad assembly, there will be inadequate contact 
between the disc and the lining (pad) until the 
pads conform to the disc.

Run-out

Excessive run-out of the discs will increase the pedal 
depression resistance due to piston kick-back.

Change in thickness (parallelism)

If the thickness of the disc changes, this will cause 
pedal pulsation, shuddering and surging.

Inset or warping (flatness)

Overheating and improper handling while servicing 
will cause warping or distortion.

BRAKE DISC THICKNESS CHECK

ACX00668

1. Using a micrometer, measure disc thickness at 

eight positions, approximately 45 degrees apart 
and 10 mm in from the outer edge of the disc.

Standard value:

<Front (LS, VR)> 20.0 mm
<Front (VR-X)> 24.0 mm
<Front (RALLIART Version-R)> 25.8 mm
<Rear> 10.0 mm

Limit value:

<Front (LS, VR)> 18.4 mm
<Front (VR-X)> 22.4 mm
<Front (RALLIART Version-R)> 23.5 mm
<Rear (VR-X)> 8.4 mm
<Rear (RALLIART Version-R)> 8.0 mm
NOTE: Thickness variation (at least 8 positions) 
should not be more than 0.015 mm.

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ON-VEHICLE SERVICE

BASIC BRAKE SYSTEM

35A-17

CAUTION

• After a new brake disc is installed, always 

grind the brake disc with on-the-car type 
brake lathe. If this step is not carried out, the 
brake disc run-out exceeds the specified 
value, resulting in judder.

•

AC006226AD

M12 Flat washer

M12 Flat washer

When the on-the-car type lathe is used, first 

install M12 flat washer on the stud bolt in the 
brake disc side according to the figure, and 
then install the adapter. If the adapter is 
installed with M12 flat washer not seated, the 
brake disc rotor may be deformed, resulting 
in inaccurate grinding.

• Grind the brake disc with all wheel nuts diag-

onally and equally tightened to the specified 
torque 100 N

⋅m. When all numbers of wheel 

nuts are not used, or the tightening torque is 
excessive or not equal, the brake disc rotor or 
drum may be deformed, resulting in judder.

2. If the disc thickness is less than the limits, replace 

it with a new one.
If thickness variation exceeds the specification, 
turn rotor with an on-the-car type brake lathe 
("MAD, DL-8700PF" or equivalent). If the 
calculated final thickness after turning the rotor is 
less than the standard value, replace the disc.

FRONT BRAKE DISC RUN-OUT CHECK 
AND CORRECTION

1. Remove the brake assembly, and then hold it with 

wire.

2. Temporarily install the disc with the hub nut.

ACX00669

3. Place a dial gauge approximately 5 mm from the 

outer circumference of the brake disc, and 
measure the run-out of the disc.

Limit: 0.06 mm

4. If the brake disc run-out exceeds the limit, correct 

it as follows:

AC201323AC

Chalk marks

(1) Chalk phase marks on the wheel stud and the 

brake disc, which run-out is excessive as 
shown.

AC314229AB

(2) Remove the brake disc. Then place a dial 

gauge as shown, and measure the axial play 
by pushing and pulling the wheel hub.

Limit: 0.05 mm

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