NHTSA ID Number: 10254365
Manufacturer Communication Number: TSB-24-35-001
TSB/Document Date: 2024-05-07
Summary
This Technical Service Bulletin provides instructions on how to resolve a concern of noise heard from the brake caliper when braking or turning.
SUBJECT:
NOISE FROM BRAKE CALIPER WHEN
BRAKING OR TURNING
No:
TSB-24-35-001
DATE:
April 2024
MODEL:
See below
CIRCULATE TO:
[ ] GENERAL MANAGER
[ X ] PARTS MANAGER
[ X ] TECHNICIAN
[ X ] SERVICE ADVISOR
[ X ] SERVICE MANAGER
[ X ] WARRANTY PROCESSOR
[ ] SALES MANAGER
PURPOSE
This TSB provides instructions on how to resolve a concern of noise heard from the brake caliper
when braking or turning. Please replace the brake pad retainer with a new improved part, upon
customer complaint basis.
BACKGROUND
When braking or turning, noise may be heard from the front brake caliper. The front brake pad
retainers have low rigidity and move with pad movement during braking conditions. This
movement may cause the retainer to become deformed and cause brake disc interference
resulting in the phenomenon.
Replacement with a new improved brake pad retainer and cleaning of the dust on the front
brake caliper is necessary. If the front disc rotor is scratched, please conduct on-car lathe
resurfacing according to rotor's usage limit parameters. If the rotor's wear limit is exceeded,
replace the front disc rotor(s).
AFFECTED VEHICLES
2022-2024 Outlander
2023-2024 Outlander Plug-in Hybrid
REFERENCED SERVICE MANUAL
• 2024* Outlander Service Manual, Volume 2, Brake System, Basic Inspection
• 2024* Outlander Plug-in Hybrid Service Manual, Volume 2, Brake System, Basic Inspection
*2024 Service Manual referenced for TSB purposes
Copyright 2024, Mitsubishi Motors North America, Inc.
The information contained in this bulletin is subject to change. For the latest version of this document, go to the Mitsubishi
Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).
4/8/2024
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PROCEDURE
Refer to the Service Manual as needed along with this bulletin to replace the CLIP SET,
FRONT with a new KIT-PAD CLIP.
Model
Outlander/
KIT-PAD
Outlander
CLIP
Plug-in Hybrid
Old Part
Part Number
Old
New
Part Name
Old
New
CLIP
SET,FRONT
41097W020P
4605C332
Quantity
Remarks
1pcs/car
1Kit contains 4
pieces. 2 pieces are
needed for each side.
New Part
NOTE: Prior to replacing or reinstalling brake pads, apply anti-friction lubricant/paste to the
contact area shown in the image below.
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6
Precaution for Brake System
Precaution for Brake System
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed with a dust collector. Never splatter the dust with an
air blow gun.
•
Brake fluid use refer to General Maintenance.
•
Never reuse drained brake fluid.
•
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. For brake component
parts, never wash them with water.
•
Always confirm the specified tightening torque when installing the brake pipes.
•
After pressing the brake pedal more deeply or harder than normal driving, such as air bleeding, check each item of brake pedal.
•
Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other components.
•
Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause improper operation.
•
Always loosen the brake tube flare nut with a flare nut wrench.
•
Tighten the brake tube flare nut to the specified torque with a crowfoot (A) and torque wrench (B).
A
B
•
CF100AJIAA00USA
Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) harness connector or the battery negative terminal before performing the work.
•
Check that no brake fluid leakage is present after replacing the parts.
•
Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
•
Front brake pad: Refer to Inspection and AdjustmentInspection and Adjustment.
•
Front disc rotor: Refer to Inspection and Adjustment.
•
Rear brake pad: Refer to Inspection and AdjustmentInspection and Adjustment.
•
Rear disc rotor: Refer to Inspection and AdjustmentInspection and Adjustment.
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PREPARATION
PREPARATION
Commercial Service Tool
Commercial Service Tool
Tool name
Description
Loosening bolts and nuts
CF100A1DAA00USA
•
Air tight
•
Inspection of check valve
Handy vacuum pump
CF100AJJAA00USA
Return the piston
CF100AJKAA00USA
Pick tool
Removing piston seal and piston boot
CF100AJLAA00USA
Lubricant or/and Sealant
Lubricant or/and Sealant
Name
Multi-purpose grease
Description
Clevis pin of brake pedal
—
•
Master cylinder assembly
•
Repair kit grease, silicone grease
MOLYKOTE® AS-880N or equivalent
Note
—
Front brake
Front: Repair kit grease, Niglube RX-2 or equivalent
•
Front brake
Rear: Repair kit grease, rubber grease or equivalent
•
Rear brake
Molykote is a registered of Dow Corning Corporation
—
4/8/2024
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BRAKE SYSTEM
8
SYSTEM DESCRIPTION
SYSTEM
WARNING/INDICATOR/CHIME LIST
Warning Light/Indicator Light
Warning Light/Indicator Light
Name
Design
Layout/Function
For layout: Refer to Design.
For function:
Brake warning light
•
For FULL TFT METER: Brake Warning LightBrake Warning Light
•
For 7 INCH INFORMATION DISPLAY: Brake Warning LightBrake Warning Light
BASIC INSPECTION
FRONT DISC BRAKE
DISC ROTOR
Inspection
Inspection
INSPECTION
Uneven wear
Uneven wear
Check the uneven wear of the disc rotor using a micrometer. Replace the disc rotor if the thickness is below the wear limit.
•
For 2WD: Refer to Removal and Installation.
•
For AWD: Refer to Removal and Installation.
CF100AJMAA00USA
Thickness variation [measure the
brake disc thickness at minimum eight
points which are 10 mm (0.39 inch)
inward from its circumference.]
4/8/2024
: Refer to Front Disc Brake.
5 of 11
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BRAKE SYSTEM
9
BRAKE CALIPER ASSEMBLY
Inspection
Inspection
INSPECTION
BRAKE DRAG FORCE CHECK
BRAKE DRAG FORCE CHECK
1.Remove the brake pad, shim cover and pad retainer (Refer to Removal and Installation).
2.Using a spring scale, measure the hub sliding torque in the forward direction with the brake pad, shim cover and pad retainer removed.
DF10000PAA
3.Install the brake pad, shim cover and pad retainer (Refer to Removal and Installation).
4.Start the engine, and depress the brake pedal lightly two or three times. Then stop the engine. [Depressing force: approximately 50 - 100 N (11.2 - 22.5 pound)]
5.Turn the brake disc 10 times in the forward direction.
6.Using a spring scale, measure the hub sliding torque in the forward direction with the brake pad, shim cover and pad retainer installed.
7.Obtain the disc brake drag force (difference between measured values of item 2 and item 6).
Standard value:
68 N (15.3 pound) or less
8.If the brake drag force exceeds the standard value, disassemble the brake caliper assembly to check for fouling/rust on the piston sliding section and piston seal deterioration, and confirm whether the
sliding pins slide properly (Refer to Disassembly and Assembly).
REAR DISC BRAKE
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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TSB/Document ID: TSB-24-35-001
Replacement Service Bulletin Number:
MFR Communication Date: 2024-04-08
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, HYDRAULIC
MFR Component System:
MFR Component Subsystem:
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