Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMITSUBISHI2004LANCER L4-2.4L SOHCREPAIR AND DIAGNOSISBRAKES AND TRACTION CONTROLDISC BRAKE SYSTEMSERVICE AND REPAIRFRONTDISASSEMBLY AND ASSEMBLY
2004 Mitsubishi Lancer L4-2.4L SOHC
Disassembly and Assembly
2004 Mitsubishi Lancer L4-2.4L SOHCSECTION Disassembly and Assembly
DISASSEMBLY STEPS
<> 1. Front Brake Bolt
<> 2. Front Brake Caliper Support (including Pad, Clip And Shim)
3. Front Brake Pin (lock Pin)
4. Front Brake Pin (Guide Pin) Assembly Or Pad Assembly
5. Front Brake Bushing
6. Pin Boot
7. Boot Ring
8. Piston Boot
9. Front Brake Caliper Piston
10. Piston Seal
11. Caliper Body
12. Pad And Wear Indicator
13. Pad Assembly
14. Inner Shim
15. Outer Shim
16. Front Brake Clip
Lubrication Points
DISASSEMBLY SERVICE POINTS
When disassembling the disc brakes, disassemble both sides (left and right) as a set.
<> PISTON BOOT/FRONT BRAKE CALIPER PISTON REMOVAL
CAUTION
Blow air little by little to remove the piston. The piston will rush out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose to remove the piston boot and piston.
<> PISTON SEAL REMOVAL
CAUTION
Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.
INSPECTION
^ Check the cylinder for wear, damage or rust.
^ Check the piston surface for wear, damage or rust.
^ Check the caliper body or sleeve for wear.
^ Check the pad for damage or adhesion of grease, check the backing metal for damage.
PAD WEAR CHECK
WARNING
Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure 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 sliding condition of the piston and slide pins.
Measure thickness at the thinnest and most worn area of the pad.
Replace the pad assembly if pad thickness is less than the limit value.
Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
<> 1. Front Brake Bolt
<> 2. Front Brake Caliper Support (including Pad, Clip And Shim)
3. Front Brake Pin (lock Pin)
4. Front Brake Pin (Guide Pin) Assembly Or Pad Assembly
5. Front Brake Bushing
6. Pin Boot
7. Boot Ring
8. Piston Boot
9. Front Brake Caliper Piston
10. Piston Seal
11. Caliper Body
12. Pad And Wear Indicator
13. Pad Assembly
14. Inner Shim
15. Outer Shim
16. Front Brake Clip
Lubrication Points
DISASSEMBLY SERVICE POINTS
When disassembling the disc brakes, disassemble both sides (left and right) as a set.
<> PISTON BOOT/FRONT BRAKE CALIPER PISTON REMOVAL
CAUTION
Blow air little by little to remove the piston. The piston will rush out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose to remove the piston boot and piston.
<> PISTON SEAL REMOVAL
CAUTION
Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.
INSPECTION
^ Check the cylinder for wear, damage or rust.
^ Check the piston surface for wear, damage or rust.
^ Check the caliper body or sleeve for wear.
^ Check the pad for damage or adhesion of grease, check the backing metal for damage.
PAD WEAR CHECK
WARNING
Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure 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 sliding condition of the piston and slide pins.
Measure thickness at the thinnest and most worn area of the pad.
Replace the pad assembly if pad thickness is less than the limit value.
Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.