Mitsubishi Car 1999-05

Brake Caliper

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Overhaul




NOTE
Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!


NOTE
Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
  2.  

  1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
  2.  
  3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
  4.  



Click image to see an enlarged view

Fig. For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



Click image to see an enlarged view

Fig. Withdraw the piston from the caliper bore

  1. For the second method, you must rotate the piston to retract it from the caliper.
  2.  
  3. If equipped, remove the anti-rattle clip.
  4.  



Click image to see an enlarged view

Fig. On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



Click image to see an enlarged view

Fig. Use a prytool to carefully pry around the edge of the boot . . .



Click image to see an enlarged view

Fig. . . . then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



Click image to see an enlarged view

Fig. Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:

  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



Click image to see an enlarged view

Fig. Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



Click image to see an enlarged view

Fig. There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

Removal & Installation





Click image to see an enlarged view

Fig. Front dual piston caliper exploded view-Diamante



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Fig. Front brake system component identification-1996-00 Galant

  1. Raise the vehicle and support safely.
  2.  
  3. Remove the appropriate tire and wheel assembly.
  4.  


NOTE
Do not let air into the master cylinder by allowing the reservoir to empty or complete system bleeding will be required.

  1. To disconnect the front brake hose, hold the nut on the brake hose side and loosen the flared brake line nut. With the hose disconnected at the line, remove the brake hose from the caliper.
  2.  
  3. Remove the caliper guide and lock pins.
  4.  
  5. Remove the caliper assembly from the caliper support.
  6.  

To install

  1. Position the brake caliper onto the caliper support.
  2.  
  3. Install and tighten the guide and lock pins.
  4.  
  5. Reconnect the brake hose.
  6.  


NOTE
Use caution not to twist brake hose during installation.

  1. Bleed the brake system.
  2.  
  3. Apply brake pedal and inspect the system for proper operation and no leakage.
  4.  
  5. Install tire and wheel assembly.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise the vehicle and support safely. Remove the wheels.
  4.  
  5. Disconnect the brake hose.
  6.  
  7. Remove the caliper lock pins and remove the caliper.
  8.  

To install:

  1. Install the brake caliper to the caliper support and torque the bolts to 65 ft. lbs. (90 Nm).
  2.  
  3. Connect the brake hose and torque to 11 ft. lbs. (15 Nm).
  4.  
  5. Refill the brake fluid as required and bleed the brakes.

    Click image to see an enlarged view

    Fig. Front disc brakes



    Click image to see an enlarged view

    Fig. Compressing the caliper pistons

  6.  

  1. As required, partially drain the master cylinder.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Caliper guide and lock pins and lift the caliper assembly from the caliper support
     

  4.  

To install

  1. Install or connect the following:

    Caliper onto the caliper support
     
    Guide pin and lock pin and tighten to specification
     
    Brake hose or banjo bolt with new washers
     

  2.  
  3. Bleed the brake system.
  4.  
  5. Install the wheels.

    Click image to see an enlarged view

    Fig. Front disc brake and related components-Diamante

  6.  

  1. As required, partially drain the master cylinder.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Caliper guide and lock pins
     
    Caliper assembly from the caliper support
     

  4.  

To install

  1. Install or connect the following:

    Brake caliper into position on the caliper support
     
    Guide and lock pins
     
    Brake hose. Bleed the brake system.
     
    Wheels
     

  2.  

  1. As required, partially drain the master cylinder.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Caliper guide and lock pins and lift the caliper assembly from the caliper support
     

  4.  

To install

  1. Install or connect the following:

    Caliper onto the caliper support
     
    Guide pin and lock pin and tighten to specification
     
    Brake hose or banjo bolt with new washers
     

  2.  
  3. Bleed the brake system.
  4.  
  5. Install the wheels.

    Click image to see an enlarged view

    Fig. Front disc brake and related components-Galant

  6.  

  1. As required, partially drain the master cylinder.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Caliper guide and lock pins
     
    Caliper assembly from the caliper support
     

  4.  

To install

  1. Install or connect the following:

    Brake caliper into position on the caliper support
     
    Guide and lock pins
     
    Brake hose. Bleed the brake system.
     
    Wheels
     

  2.  

  1. As required, partially drain the master cylinder.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose
     
    Caliper guide and lock pins
     
    Caliper assembly from the caliper support
     

  4.  

To install

  1. Install or connect the following:

    Brake caliper into position on the caliper support
     
    Guide and lock pins
     
    Brake hose. Bleed the brake system.
     
    Wheels

    Click image to see an enlarged view

    Fig. Front disc brake and related components-Mirage

     

  2.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake hose from the caliper
     
    Caliper guide and lock pins and lift the caliper assembly from the caliper support
     

  4.  

To install

  1. Install or connect the following:

    Caliper onto the caliper support
     
    Guide pin and lock pin and tighten to specification
     
    Brake hose or banjo bolt with new washers
     

  2.  
  3. Bleed the brake system.
  4.  
  5. Install the wheels.
  6.  


    Click image to see an enlarged view

    Fig. Front disc brakes-Diamante



    Click image to see an enlarged view

    Fig. Front disc brakes-Galant


Evolution
  1. As required, partially drain the master cylinder.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Disconnect and plug the brake hose connection. Discard the gasket.
  8.  
  9. Remove the caliper retaining bolts. Remove the caliper from the vehicle.
  10.  

To install

  1. Position the caliper to its mounting on the vehicle.
  2.  
  3. Install the caliper retaining bolts.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Be sure to check and adjust the brake fluid level, as necessary.
  8.  
  9. Bleed the brake system, as necessary.
  10.  

 
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