1991 MITSUBISHI ECLIPSE boot

3-18REAR AXLE - Drive Shaft
ring
\
Inner race
1180116
llE507
7.(4) Secure the B.J. boot with boot bands (A) and
(C) to the
drive shaft and B.J.
Caution
-Ensure that the B.J. is at a zero angle with the drive
shaft to ensure the boot contains the specified
amount of air.
INSTALLATION OF D.O.J. INNER RACE, CAGE AND
BALL ASSEMBLY
(1) Apply the specified grease to the D.O.J. cage, the balls
and the D.O.J. inner race.
Specified grease:Repair kit grease (As required)
(2) Install the cage, balls and inner race to the drive shaft,
then, using the snap ring pliers, fit the snap ring
securely into the groove in the shaft.
5. APPLICATION OF GREASE TO D.O.J. OUTER RACE
(1) Fill the specified grease to the D.O.J. outer race, fit the
drive shaft into the D.O.J. outer race, and then fill moregrease to the D.O.J. outer race.
Specified grease: Repair kit grease
90 g (3.2 oz.)
Caution
The grease in the repair kit should be divided in halffor use, respectively, at the joint and inside the
boot.A special type of grease is used on the joint. Be
cautious to ensure that no other grease is allowed
to come in contact with the joint.
(2) Install the
circlip to the D.O.J. outer race.
(3) Assemble the D.O.J. boot to the D.O.J. outer race, thensecure the boot to the drive shaft with boot band
(C).(4) Place boot band
(B) on the D.O.J. boot.
NOTEDo not secure boot band
(9)(5) Set the D.O.J. boot bands at the specified distance in
order to adjust the amount of air inside the D.O.J. boot,and then tighten the D.O.J. boot band
(C) securely.
Standard value: 76+-3 mm (3.00
& .23 in.)
(6) Release a part of the D.O.J. boot from the D.O.J. outer
--race to allow pressure to escape from the boot.
(7) Tighten boot band
(9) and secure the D.O.J. boot.
Boot band
(8’)

5-6BRAKES - Specifications/Special Tools
ItemsBrake piston seal
Brake piston boot inner surfaces
Brake lock pin boot inner surfaces
Guide pin boot inner surfaces
Guide pin and caliper support contact surface
Lock pin and caliper support contact surface
Spindle lever, lever boot, connecting link,
O-ring and auto adjuster spindle
SPECIAL TOOLSSpecified lubricant
Repair kit grease (orange)
Rear disc brake
Pressing of the rear disc brake pistons
Sliding hammer set

BRAKES - Service Adjustment Procedures5-47
14AO399-6. Clean piston and insert into cylinder with tool.
7. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin.8. Check brake drag torque as follows.
(1) Start engine and hold brake pedal down for 5 seconds.
(2) Stop engine.
(3) Turn brake disc forward
10 times.
(4) Check brake drag torque with spring scale.
If the difference between brake drag torque and hub torqueexceeds the standard value, disassemble piston and clean
the piston. Check for corrosion or worn piston seal, and
check the sliding condition of the lock pin and guide pin.
Standard value: 70
N (15 Ibs.) or less
[4 Nm (3 ftlbs.)] or less
FRONT BRAKE DISC THICKNESS CHECK
NQ5FRASRemove dirt and rust from brake disc surface. Measure disc
thickness at 4 locations or more.
Limit: 22.4 mm
(.882 in.)
Replace the discs and pad assembly for both sides left and
right of the vehicle if they are worn beyond the specified limit.
FRONT BRAKE DISC RUN-OUT CHECKNOIFSAB
1.Remove the caliper support; then raise the caliper assem-
bly upward and secure by using wire.
2. Place a dial gauge approximately 5 mm
(2 in.) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit: 0.08 mm
(.0031 in.)
NOTETighten the nuts in order to secure the disc to the hub.

BRAKES - Service Adjustment Procedures5-494. Remove the following parts from caliper support.
14AO405
14AOs
grooves
Q
0 0
Projection
14R0037
14A0401
14AO406
MAO204Outer shim
Pad assembly
Pad clips
CPad clips
B
5.Measure hub torque with pad removed to measure brake
drag torque after pad installation.
NOTETo secure the disc to the hub, tighten the nuts.
6. Securely attach the pad clip to the caliper support.
Caution
Do not deposit grease or other dirt on pad or brake disc
friction surfaces.7. Clean the piston; then use the special tool to thread the
piston into the cylinder.
Be sure, at this time, that the stopper groove of the piston
correctly fits to the projection on the pad’s rear surface.
8. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the lock pin.
With the engine running, forcefully depress the brake pedalfive or six times, and then check whether or not the stroke
of the parking brake lever is within the standard value.
If there is a deviation from the standard value, adjust the
stroke of the parking brake lever.
(Refer to
P.5-42.)9. Check brake drag torque as follows.
(1) Start engine and hold brake pedal down for 5 seconds.
(2) Stop engine.
(3) Turn brake disc forward 10 times.
(4) Check brake drag torque with spring scale.
If the difference between brake drag torque and hub torqueexceeds the standard value, disassemble piston and clean
piston. Check for corrosion or worn piston seal, and check
the sliding condition of the lock pin sleeve and guide pin
sleeve.Standard value: 70
N (15 Ibs.) or less
[4 Nm (3 ft.lbs)] or less
REAR BRAKE DISC THICKNESS CHECKNOSWAB
1. Remove dirt and rust from brake disc surface.
2. Measure disc thickness at 4 locations or more.
Limit: 8.4 mm
(.331 in.)
Replace the discs and pad assembly for both sides left andright of the vehicle if they are worn beyond the specified
limit.

BRAKES -Front Disc Brake5-67DISASSEMBLY AND REASSEMBLY
64-86
46-62
64-86
46-62
ft.lbs. ;
Caliper assembly disassembly steps
l + 1. Guide pin
l + 2. Lock pin
l + 3. Bushing
4. Caliper support (Pad, clip, shim)
e+ 5. Guide pin boot
l 6. Lock pin boot
::7. Boot ring
8. Piston boot
l *** 9. Piston
4I) l + 10. Piston sealIl. Brake hosel + 12. Caliper body
Pad assembly disassembly steps
l + 1. Guide pin
l + 2. Lock pinl * 3. Bushing
4. Caliper support (Pad, clip, shim)
13. Pad and wear indicator assembly
14. Pad assembly15. Outer shim
16. Clip
NOSLE-B
.16
(1) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) l O : Refer to “Service Points of Reassembly”.(4) m : Non-reusable partsBrake caliper kit
3Pad repair kitSeal and boots
repair kit
14
106
13
13
1614
1614AO539
514A054(3

5-68BRAKES - Front Disc Brake
14KO5414GOO54
14K057
14UOO72
SERVICE POINTS OF DISASSEMBLYNO5LFAJWhen disassembling the front disc brakes, disassemble both
sides (left and right) as a set.
7. REMOVAL OF BOOT RINGRemove boot ring with flat tip
(-) screwdriver.
8. REMOVAL OF PISTON
BOOT/g. PISTON
Protect caliper body with cloth. Blow compressed air
through brake hose to remove piston boot and piston.
Caution
Blow compressed air gently.
10. REMOVAL OF PISTON SEAL(1) Remove piston seal with finger tip.
Caution
Do not use flat tip (-) screwdriver or other tool to
prevent damage to inner cylinder.(2) Clean piston surface and inner cylinder with
trichloro-ethylene, alcohol or specified brake fluid.
Specified brake fluid: MOPAR Brake Fluid/
Conforming to DOT3
INSPECTIONNOSLGAJl Check cylinder for wear, damage or rust.
l Check piston surface for wear, damage or rust.
l Check caliper body guide pin or lock pin for wear.
l Check pad for damage or adhesion of grease, check
backing metal for damage.
PAD WEAR CHECKMeasure thickness at the thinnest and worn area of the pad.
Replace pad assembly when pad thickness is less than the limit
value.Limit value: 2.0 mm
(.08 in.)

14KO60Do not wipe special grease on piston seal.
BRAKES - Front Disc Brake5-69
SERVICE POINTS OF REASSEMBLYNOSLli@
12. APPLICATION OF BRAKE FLUID TO CALIPER BODYApply specified brake fluid to inner cylinder.
Specified brake fluid: MOPAR Brake Fluid/
Conforming to DOT3
10. INSTALLATION OF PISTON SEALInstall piston seal in cylinder groove.
Caution
9. INSTALLATION OF PISTON
(1) Apply specified brake fluid to piston. Insert into cylinder
without twisting.
Specified brake fluid: MOPAR Brake Fluid/
Conforming to DOT3Piston boot’
14KO70
I
Grease
II14A0541 I(2) Fill piston edge with specified grease. Install piston
boots.
Specified grease: Repair kit grease (orange)6. APPLICATION OF GREASE TO LOCK PIN
BOOT/5.GUIDE PIN
BOOT/3. BUSHING
Grease parts as illustrated with specified grease.
Specified grease: Repair kit grease (orange)
2. INSTALLATION OF LOCK PIN/l. GUIDE PIN
Install the guide pin and lock pin so the identification mark
on the caliper body and head mark on the guide pin and lockpin are aligned.

BRAKES -Rear Disc Brake5-73
IISASSEMBLY AND REASSEMBLY
125-35 Nm
18-25 ft.lbs.
;
I13-17 Nm
9-12
ftlbs.
c*:O55 Nm29-40 ft.lbs.22-32 Nm
16-23 fi.J,,s.b- Q \\T;17-9 Nm
5-7
ft.lbs.
GreaseBrake seal kit
Caliper assembly disassembly steps
1. Connection for brake hose
2. Lock pin
N 4. Lock pin sleeveM 5. Lock pin boot
l 6. Guide pin boot
7. Boot ring
l + 8. Piston boot+e W+ 9. Piston assembly** l + 10. Piston seal
l * l + Il. Snap ring12. Spring case
13. Return spring14. Stopper plate
15. Stopper
~~ 16. Auto-adjuster spindleI)+ 17. Connecting link
I)+ 18. O-ringl + 19. Spindle leverl + 20. Lever boot21. Parking brake lever22. Return spring
23. Bleeder screw
24. Caliper body
Pad
assembly disassembly steps
1. Lock pinNm
Iftlbs.293.2
*I)3. Support mounting (pad, shim, clip)
25.Outer shim26.Pad assembly27. Padclips C28. Pad clips BNOTE
29. Guide pin
30. Guide pin sleeve
31. Support mounting
(I) Reverse the disassembly procedures to reassemble.(2) l I) : Refer to “Service Points of Disassembly”.(3) H : Refer to “Service Points of Reassembly”.(4) 19 : Non-reusable parts26
25
26
25
Brake pad kit
14AO219