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Gen1 Montero SWB 4-cylinder front brake upgrade
#1074822
10/23/14 02:24 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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I've seen some threads on the swap, but nothing from the small 4-cylinder brakes to Gen2 brakes, and nothing that I would consider a "how to", so here it is. I had my front right caliper seize up on me, so rather than replace it with another anemic caliper, I decided to swap in the Gen 2 brakes. I used rotors, pads, and calipers from a 1998 Montero Sport. Master Cylinder from a 1998 Montero Sport as well. You will also need to replace the bolts that join the hub and brake rotor, as you will see. New brake lines (I bought -3an stainless lines & M10 to -3an adaptors on each end) ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0196s_zpscf654395.jpg) Look at how pathetic those brakes look compared to the tires! <img src="/forums/images/graemlins/lol.gif" alt="" /> ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0197s_zps8f6354b2.jpg)
Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074823
10/23/14 02:37 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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First step is to remove the brake caliper & bracket, then start taking apart the locking hubs. ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0204s_zps6f60b204.jpg) Unbolt and remove the locking mechanism. Remove the circlip from the end of the axle shaft. ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0215s_zps57bb1954.jpg)
Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074824
10/23/14 02:45 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Remove all the bolts And remove the body of the locking hubs. ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0218s_zpsc8cc5b56.jpg) Remove the 2 screws on the nut retainer They may be pretty tight, so a proper impact screwdriver is a huge help And then remove the nut retainer. The nut *should* be fairly loose, so you should be able to spin it off with a small screwdriver in one of the holes. ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0226s_zps113894ba.jpg)
Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074825
10/23/14 02:52 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074826
10/23/14 02:57 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074827
10/23/14 03:04 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074828
10/23/14 03:17 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074829
10/23/14 03:35 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074830
10/23/14 03:49 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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Now... it's time to get dirty! - well, full of grease anyway. My grease of choice for this job... Pack the center of the hub, between where the 2 bearings sit with grease I won't go into how to pack bearings with grease... There are plenty of tools, or YouTube videos on how to do that. Install the rear packed bearing, and install the new rear grease seal. Once you have that done, reinstall the rotor/hub assembly on the vehicle. Make sure you smear a little grease on the lip of the rear seal before installing Then install the outer bearing And then the ring nut Hand tighten the nut while turning the rotor ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0291s_zps4f4508ba.jpg)
Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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Re: Gen1 Montero SWB 4-cylinder front brake swap
[Re: Struc]
#1074831
10/23/14 04:11 AM
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Joined: Apr 2013
Posts: 75
OP
Getting the Wheeling Fever
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You need a special tool to tighten the nut to spec. I opted to buy this one (which came with 4 prongs instead of 2), and to take my cut off tool to 2 of the prongs. Use the tool to tighten the hub nut to 94-145 ft lbs per the manual. I like to do this in steps while turning the rotor in the early part to make sure the bearings seat properly. Once torqued down, loosen the nut completely, and then re-torque to 18 ft lbs. Then, loosen 30 to 40 degrees (less than 1/8th turn). According to the manual, you are then supposed to measure the amount of force it takes to turn the hub assy. I didn't personally bother, but if you have the tool, by all means go ahead. Spring scale reading should be 1.1 to 4 lbs. Once all that is done, install the lock washer and install the 2 screws. ![[Linked Image]](http://i544.photobucket.com/albums/hh339/cshambeau/Montero%20Brake%20Swap/IMG_0295s_zpse026f7c9.jpg)
Curt Shambeau 87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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