1998 MITSUBISHI MONTERO brake rotor

Removal & Installation (3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
clip, brake pad retaining pins and spring. See Fig. 17. Remove shims
and pads from caliper. Keep track of location of shims for reassembly.
2) Compress caliper pistons fully in bores. Install shims on
brake pads. Install brake pads. Install spring clip, pad retaining
pins and clip. Start engine and depress brake pedal several times to
expand caliper piston. Check brake fluid level.
FRONT BRAKE CALIPER
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.
Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Bleed brake system. See
BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal & Installation (Except Montero & Montero Sport)
Raise vehicle, and remove wheel(s). Remove caliper. See
FRONT BRAKE CALIPER . Slide rotor off hub. To install, reverse removal
procedure.
Removal (Montero & Montero Sport)
Raise and support vehicle. Remove brake caliper. See
FRONT BRAKE CALIPER . On 4WD, remove Remove bearing grease cap, snap
ring, shim, 6 bolts and drive flange from axle shaft. On 2WD remove 6
bolts and hub cover. Remove screw(s) from lock washer. Remove lock
washer. Remove lock nut using Lock Nut Wrench (MB990954). Remove hub
assembly. Place match marks on rotor and hub. Remove rotor from front
hub.
Installation
1) Install rotor on hub. Service wheel bearings and seals as
necessary. Install front hub assembly. Install lock nut, and tighten
it to 119 ft. lbs. (165 N.m). Loosen lock nut, and retighten it to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Install lock washer
and screw(s).
2) On 2WD, reverse removal procedure for remaining
components. On 4WD, install drive flange, shim and snap ring. Using
feeler gauge, check axle shaft-to-hub clearance. Clearance should be
0.016-0.028" (0.41-0.71 mm). Use appropriate shim to obtain correct
clearance. Shim is located behind snap ring on end of axle shaft.
Recheck clearance if necessary. Install remaining components.
PARKING BRAKE SHOES
Removal & Installation (Diamante)
1) Raise and support vehicle. Remove rear wheels. Remove rear
disc brake caliper and rotor. If rotor removal is difficult, rotate
rotor until hole in rotor is upward. Back-off brake shoe adjustment
with a flat blade screwdriver through hole in rotor.
2) Disconnect rear speed sensor. See Fig. 9. Remove 4 bolts
and hub. Remove screw and shoe hold-down spring. Remove shoe. To
install, reverse removal procedure. Adjust brake shoe by turning
adjuster star wheel.

Removal (Eclipse, Montero & Montero Sport)
1) Raise and support vehicle. Remove rear wheels. Disconnect
rear speed sensor (if equipped). Remove rear disc brake calipers and
rotors. See REAR BRAKE CALIPER .
2) Remove adjuster spring. Remove shoe hold-down cup, spring
and pin. See Fig. 10. Note how shoe-to-anchor spring is installed, and
then remove adjuster and shoe-to-anchor spring. Remove strut and
return spring. Remove clip and shoe and lining assembly.
Fig. 9: Exploded View Of Parking Brake Assembly (Diamante)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Exploded View Of Parking Brake Assembly (Typical With Rear
Disc Brakes - Except Diamante)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Shoe-to-anchor spring must be installed correctly for proper
functioning of parking brakes.
Installation
1) To install, reverse removal procedure. When installing
shoe-to-anchor spring, ensure spring is installed correctly. When
installing adjuster, install left adjuster with adjusting bolt facing
vehicle front and right adjuster with adjusting bolt facing vehicle
rear.
2) On models with ABS, ensure gap between rotor teeth and
speed sensor pole piece is 0.008-0.039" (0.20-1.00 mm).
Removal (3000GT)
1) Raise and support vehicle. Remove rear wheel(s).
Disconnect rear speed sensor. Remove rear disc brake calipers and

rotors. See REAR BRAKE CALIPER .
2) On FWD models, remove grease cap, hub nut and hub. On AWD
models, disconnect rear axle from companion flange at hub. Remove axle
hub nut. Using slide hammer and Hub Adapter (MB991354), remove axle
from knuckle.
3) On all models, remove adjusting wheel spring. Remove shoe
hold-down cup, spring and pin. Note how shoe-to-anchor spring is
installed, and then remove adjuster and shoe-to-anchor spring. Remove
strut and return spring. Remove clip and shoe and lining assembly.
CAUTION: Shoe-to-anchor spring must be installed correctly for proper
functioning of parking brakes.
Installation
To install, reverse removal procedure. When installing shoe-
to-anchor spring, ensure spring is installed correctly. When
installing adjuster, install left adjuster with adjusting bolt facing
vehicle front and right adjuster with adjusting bolt facing vehicle
rear. On AWD, tighten companion flange nut to 188-217 ft. lbs. (260-
300 N.m).
REAR DISC BRAKE PADS
NOTE: Replace inner and outer pads at same time.
Removal
Raise and support vehicle. Remove rear wheels, and disconnect
parking brake cable. Remove lower lock pin bolt. Lift caliper body
upward. Using a wire, support caliper aside. Remove inner shims, anti-
squeak shim and pad assembly from support mounting. Remove pad clips.
Installation
Rotate piston to align notches in piston projection on back
of pads (if equipped). Install retaining clips, pad assembly, inner
shims and anti-squeak shim onto support mounting. Lower caliper body,
and install lock pin.
REAR BRAKE CALIPER
Removal
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.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Bleed brake system. See
BLEEDING BRAKE SYSTEM .
REAR BRAKE ROTOR
Removal & Installation
Raise and support vehicle. Remove rear caliper. See
REAR BRAKE CALIPER . Remove rotor. To install, reverse removal
procedure.
REAR BRAKE DRUM & SHOES
Removal
1) Raise and support vehicle. Remove wheels. Remove brake
drum from hub. If drum is difficult to remove, back-off shoe adjuster

cavity and contact surfaces. Install oil seal using seal driver. Press
new oil seal into bearing case until it is flush with face of bearing
case. Install backing plate and bearing case.
2) Apply grease to external surfaces of bearing outer race.
Press bearing outer race into bearing case. Install rear brake
assembly and bearing case. Pack bearing case and axle threads with
grease. Install new retainer ring and snap ring.
3) Using a feeler gauge, measure clearance between snap ring
and new retainer ring. Clearance should be less than 0.0065" (0.165
mm). If clearance exceeds specification, install a new selective snap
ring to bring clearance to specification. See SNAP RING THICKNESS
SPECIFICATION table.
SNAP RING THICKNESS SPECIFICATION









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Thickness: In. (mm) Color\
0.060 (1.52) ................................................... Red\
0.067 (1.70) ................................................ Purple\
0.073 (1.85) .................................................. Blue\
0.079 (2.01) ................................................ Yellow\
0.085 (2.16) ............................................... Neutral\









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4) Check condition of oil seal and replace as necessary.
Install axle shaft assembly into axle housing. Tighten bearing
retainer bolts to 65 ft. lbs (15 N.m.). To complete installation,
reverse removal procedure.
REAR AXLE HUB BEARINGS
NOTE: Rear hub bearings are not serviceable on FWD models.
Removal & Installation (FWD Models)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). On models with drum brakes, remove brake
drum and shoes. See REAR BRAKE DRUM & SHOES .
2) On models with disc brakes, remove caliper and rotor. On
all models, remove hub bolts or spindle nut and hub assembly. To
install, reverse removal procedure. Tighten hub bolts or spindle nut
to specification. See HUB TIGHTENING TORQUE table. Rotate brake drum
or disc to ensure free movement.
NOTE: Rear hub bearings are not serviceable on Eclipse AWD models.
Removal & Installation (Eclipse AWD)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). On models with drum brakes, remove brake
drum and shoes. See REAR BRAKE DRUM & SHOES .
2) On models with disc brakes, remove caliper and rotor. On
all models, remove axle nut. Remove 4 hub bolts and hub assembly. To
install, reverse removal procedure. Tighten hub bolts to
specification. See HUB TIGHTENING TORQUE table. Rotate brake drum or
disc to ensure free movement.
HUB TIGHTENING TORQUE









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Application Ft. Lbs. (N.m)\
Hub Mounting Bolts ................................... 54-65 (74-85)\
Spindle Nut
Mirage ................................................. 127 (172)\
3000GT FWD ............................................. 170 (230)\

AXLE SHAFT R & I
Removal (Montero & Montero Sport)
Block front wheels. Raise and support rear axle housing.
Remove brake caliper and rotor. See Fig. 3. Remove parking brake cable
attaching bolts. Remove connection for parking brake cable end from
rear brake assembly. Remove ABS speed sensor (if equipped). Unbolt
backing plate with bearing housing from rear axle housing. Using
Puller (MB990241) and Slide Hammer (MB990211), remove axle assembly.\
DO NOT damage oil seal. Remove "O" ring. Replace if necessary.
Installation
Install NEW oil seal in axle housing as needed. To install
axle assembly, reverse removal procedure.
Fig. 3: Exploded View Of Typical Axle Shaft
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Insert new "O" ring and shim of .04" (1.0 mm) thickness

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outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
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Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole
in it through which exhaust gases are leaking. Replacement
of the exhaust pipe in this case is required due to
functional failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.

Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement. Although
this list is extensive, it is not fully inclusive. In addition to this
list, a technician may make a suggestion. However, any suggestions
must be based on substantial and informed experience, or the vehicle
manufacturer's recommended service interval and must be documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole
in it through which exhaust gases are leaking. Replacement of
the exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.