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Gen1 Montero SWB 4-cylinder front brake upgrade #1074822 10/23/14 02:24 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
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]

Look at how pathetic those brakes look compared to the tires! <img src="/forums/images/graemlins/lol.gif" alt="" />

[Linked Image]


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
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
First step is to remove the brake caliper & bracket, then start taking apart the locking hubs.

[Linked Image]

Unbolt and remove the locking mechanism.

[Linked Image]

Remove the circlip from the end of the axle shaft.

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074824 10/23/14 02:45 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
[Linked Image]

Remove all the bolts

[Linked Image]

And remove the body of the locking hubs.

[Linked Image]

Remove the 2 screws on the nut retainer

[Linked Image]

They may be pretty tight, so a proper impact screwdriver is a huge help

[Linked Image]

And then remove the nut retainer.

[Linked Image]

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]

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074825 10/23/14 02:52 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
At this point, you should be able to pull off the hub & rotor assembly.

[Linked Image]

[Linked Image]

[Linked Image]

Clean off all the old grease

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074826 10/23/14 02:57 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
If you are not replacing the shield, it needs to be trimmed back to fit the new calipers.

[Linked Image]

[Linked Image]

I used my air cut off tool, but tin snips should work as well.

[Linked Image]

[Linked Image]

Finished Product:

[Linked Image]

[Linked Image]

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074827 10/23/14 03:04 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
Time to clean up and inspect the bearings

[Linked Image]

And pull and replace the rear grease seal

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

Dig out all the old grease

[Linked Image]

Cut apart plastic container (in this case, laundry detergent) for a parts cleaning bucket and a can of brake cleaner, and CLEAN!

[Linked Image]

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074828 10/23/14 03:17 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
Time to pull the hub apart from the brake rotor

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074829 10/23/14 03:35 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
Some pictures comparing the old small rotors to the new larger ones.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

As you can see, the old bolts that hold the rotor to the hub have a unthreaded shank that is too long, and they cannot be used.

[Linked Image]

Replace with new shorter HARDENED bolts, and new washers and nuts.

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074830 10/23/14 03:49 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
Now... it's time to get dirty! - well, full of grease anyway. My grease of choice for this job...

[Linked Image]

[Linked Image]

Pack the center of the hub, between where the 2 bearings sit with grease

[Linked Image]

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.

[Linked Image]

[Linked Image]

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

[Linked Image]

Then install the outer bearing

[Linked Image]

And then the ring nut

[Linked Image]

Hand tighten the nut while turning the rotor

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074831 10/23/14 04:11 AM
Joined: Apr 2013
Posts: 74
Struc Offline OP
Getting the Wheeling Fever
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.

[Linked Image]

[Linked Image]

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]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
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