Disc - Evolution: Removal & Installation Mitsubishi Lancer IX

Removal & Installation

1. Raise and support vehicle. Remove front wheels. While holding caliper cross spring, pull pins out of caliper. see scheme 14 Remove shims and pads from caliper.
2. If installing new pads, compress piston to bottom of bore using Disc Brake Piston Expander (MB990520). Apply repair kit grease to sides of pads. Ensure grease is not applied to any other surfaces. Install brake pads and pins. Start engine and depress brake pedal several times to expand caliper piston. Check brake fluid level.

Removal

Raise and support vehicle. Remove front wheels. Remove hose clip from brake hose mount (if equipped). Disconnect brake hose from caliper. Remove upper and lower caliper-to-steering knuckle bolts. Remove caliper.

Installation

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

Raise vehicle, and remove wheel(s). Remove caliper. See FRONT BRAKE CALIPER . Slide rotor off hub. To install, reverse removal procedure.

Drain brake fluid from master cylinder. Remove air cleaner and air intake hose. Remove strut tower bar. Disconnect brake fluid level sensor connector. Disconnect brake lines from master cylinder, and install plugs to prevent brake fluid spillage. Remove master cylinder-to-booster nuts, and remove master cylinder.

To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS . After installation, adjust pedal height. See BRAKE PEDAL HEIGHT under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM .

Scheme 18

1. (Scheme 18)for removal and installation. Remove rear floor console and rear console bracket. Remove rear seat cushion.
2. Remove parking brake shoes. See «PARKING BRAKE SHOES»(ref-163016-S24604716832004061600000).
3. Remove clip and parking brake cable from backing plate. (Scheme 20)
4. Disconnect parking brake cable from parking brake lever. See «PARKING BRAKE LEVER»(ref-163016-S36936211862004061600000). Remove cable bracket bolts and parking brake cable.
5. To install, reverse removal procedure. Check parking brake lever stroke, and adjust as necessary. See «PARKING BRAKE LEVER STROKE»(ref-163016-S29501037062004061600000) under ADJUSTMENTS.

Scheme 19

1. Remove floor console assembly and rear console bracket. Remove adjusting nut. (Scheme 19) Disconnect parking brake switch connector.
2. Disconnect parking brake cable from parking brake lever. Remove mounting bolts and parking brake lever assembly. Remove parking brake switch from parking brake lever assembly.
3. To install, reverse removal procedure. Check parking brake lever stroke, and adjust as necessary. See «PARKING BRAKE LEVER STROKE»(ref-163016-S29501037062004061600000) under ADJUSTMENTS.

Scheme 20

1. Raise and support vehicle. Remove rear wheels. Remove rear disc brake caliper and rotor. See «REAR BRAKE ROTOR»(ref-163016-S33415116572004061600000).
2. Remove rear hub. Remove the following: (Scheme 20) Shoe return springs. Shoe guide plate. Shoe auto adjuster spring. Shoe slack adjuster. Parking brake operating lever strut. Shoe-to-strut spring. Shoe spring cup. Shoe hold-down spring. Brake shoe assembly.
3. To install, reverse removal procedure. When installing adjusters, ensure that shoe adjusting bolt on left side is attached toward rear of vehicle and shoe adjusting bolt on right side is attached toward front of vehicle.
4. Ensure Yellow shoe return spring is installed on rear side and Blue shoe return spring is installed on front side.
5. Check parking brake lever stroke, and adjust as necessary. See «PARKING BRAKE LEVER STROKE»(ref-163016-S29501037062004061600000) under ADJUSTMENTS.
6. Perform parking brake lining seating procedure. See «PARKING BRAKE LINING SEATING PROCEDURE»(ref-163016-S41168329072004061600000).

Remove brake master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from power brake booster. Disconnect clevis pin attaching brake pedal to power brake booster push rod. From inside vehicle, remove 4 nuts attaching power brake booster to firewall. Remove power brake booster.

Check brake booster push rod protruding length, and adjust if necessary. See BRAKE BOOSTER PUSH ROD under ADJUSTMENTS. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Install master cylinder. Bleed brake system if necessary.

Loosen clamps, and remove vacuum hose/check valve assembly. Install vacuum hose/check valve assembly with white-marked sections facing up. Insert securely and completely until vacuum hose at engine side contacts edge of hexagonal part of fitting, and then secure with hose clamps.

Raise and support vehicle. Remove rear wheels. Remove pins. see scheme 15 Remove inner shims, anti-squeak shim and pad assembly from support mounting. Remove pad clips.

If installing new pads, compress piston to bottom of bore. Install retaining clips, pads and shims. Install pins. Start engine and depress brake pedal several times to expand caliper piston. Check brake fluid level.

Raise and support vehicle. Remove rear wheels. Disconnect brake hose from caliper. Cap end of brake line to prevent spillage. Remove upper and lower caliper mounting bolts. Lift caliper body upward. Remove caliper.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

Raise and support vehicle. Remove rear caliper. See REAR BRAKE CALIPER . Remove rotor. To install, reverse removal procedure.