Mitsubishi Lancer Evolution X. Manual - part 132

FRONT DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-33

NOTE: Install the brake pad assembly (with wear 
indicator) to outside the vehicle.

LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS

.

<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION

Do not remove one piston completely before trying to 
remove the other piston, because it will become impossi-
ble to remove other pistons.
Remove the pistons by pumping in air slowly from the brake 
hose connection. Be sure to use a wood block and adjust the 
height of the four pistons so that the pistons protrude evenly.

.

<<B>> PISTON SEAL REMOVAL

CAUTION

To prevent damage to inner cylinder, do not use a 
flat-tipped screwdriver or other tool.
1. Remove the piston seal with finger tip.
2. Clean the piston surface and cylinder inner face with alcohol 

or specified brake fluid.

Brake fluid: DOT3 or DOT4

<<

A

>>

7.

Piston boot

<<

A

>>

8.

Piston

<<

B

>>

9.

Piston seal

 

10. Caliper body

Disassembly steps (Continued)

AC707832AC

Grease: Repair kit grease (Color: Copper), 
              Molykote 7439 or equivalent

Grease: Repair kit grease (Color: Black), 
              Molykote AS880N or equivalent 

AC604930AB

Wood block

FRONT DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-34

INSPECTION

M1351006300680

• 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). Fail-
ure 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: 9.85 mm (0.39 inch)
Limit: 2.0 mm (0.08 inch)

AC709429

REAR DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-35

REAR DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351007000790

CAUTION

Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched. 
And if there is brake fluid on the caliper, wipe it off quickly.

Pre-removal Operation
Brake fluid draining

Post-installation Operation
• Brake fluid supplying and air bleeding (Refer to 

P.35A-16

).

• Brake disk runout inspection/correction (Refer to 

P.35A-21

).

• Parking brake lining seating procedure (Refer to GROUP 

36 − Parking Brake Lining Seating Procedure 

P.36-9

).

AC707657AB

6

7

3

1

4

5

8

2

N

30 ± 5 N·m
22 ± 3 ft-lb

80 ± 10 N·m
59 ± 7 ft-lb

16 ± 3 N·m
12 ± 2 ft-lb

11 ± 2 N·m
98 ± 17 in-lb

Removal steps 

1.

Brake hose (brake caliper side) 
connection

2.

Gasket

3.

Rear brake caliper assembly

<<

A

>>

4.

Rear brake disk

5.

Adjusting hole plug

6.

Clip

7.

Brake hose (brake pipe side) 
connection

8.

Brake hose

Removal steps (Continued)

REAR DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-36

REMOVAL SERVICE POINT

.

<<A>> FRONT BRAKE DISK REMOVAL

If the rear brake disk removal is difficult, install bolts (M8 x 1.25 
mm) shown in the figure, and tighten them evenly and gradually 
to remove the rear brake disk.

INSPECTION

M1351007100399

.

BRAKE DISC CHECK

• Disc wear (Refer to 

P.35A-21

).

• Disc run-out (Refer to 

P.35A-21

).

AC707776AB

Bolts (M8 x 1.25 mm)