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Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074832
10/23/14 04:20 AM
10/23/14 04:20 AM
Struc  Offline OP
Getting the Wheeling Fever
Joined: Apr 2013
Posts: 74
Oconomowoc, WI
Time to clean up the locking hubs.

[Linked Image]

Remove the snap ring holding everything together

[Linked Image]

Once apart, clean all the parts. There is another snap ring holding the remaining parts together.

[Linked Image]

[Linked Image]

Reassemble the reverse way, and apply a thin layer of grease to all the parts.


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] #1074833
10/23/14 04:26 AM
10/23/14 04:26 AM
Struc  Offline OP
Getting the Wheeling Fever
Joined: Apr 2013
Posts: 74
Oconomowoc, WI
If you keep the dust shield like I did, you'll probably need to bend up the lip for clearance a little.

[Linked Image]

Install the Caliper bracket, caliper, and pads. Be sure to put a thin layer of grease on the pad hardware.

[Linked Image]

I also use grease on the back of the pads to help eliminate any brake squeal.

[Linked Image]

And... Installed!

[Linked Image]


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074834
10/23/14 04:36 AM
10/23/14 04:36 AM
Struc  Offline OP
Getting the Wheeling Fever
Joined: Apr 2013
Posts: 74
Oconomowoc, WI
Install the locking hub body.

[Linked Image]

Install the circlip to the end of the axle. PLEASE NOTE that it only goes on one way. There is a flat and rounded side to the circlip. It's been a while since I did this, but if I remember correctly, the flat side faces out toward you.

[Linked Image]

If you take apart the locking mechanism, PLEASE note that there is a little detent ball and spring. DON'T lose them!

[Linked Image]

Reinstall the locking hub mechanism, and you're nearly done.


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074835
10/23/14 04:53 AM
10/23/14 04:53 AM
Struc  Offline OP
Getting the Wheeling Fever
Joined: Apr 2013
Posts: 74
Oconomowoc, WI
I neglected to take many pictures of my brake line setup, but here are some stock pictures, and a couple of actual pictures of what I used, and where.

For the caliper, Earl's Performance 592032ERL Fittings:

[Linked Image]

For where the hard line comes down into the wheel well area, Earl's 989538ERL or 989545ERL fitting:

[Linked Image]

Used here:

[Linked Image]

and then used a -3an stainless line with a 90 degree bend on one end (caliper end). The ones I got were 21" long. You could probably get away with 18", as long as one end has the 90 degree bend.

[Linked Image]

[Linked Image]

This all eliminates the 3 piece brake line setup that is stock. I ran the stainless line through the bracket, wrapped some electrical tape on it to prevent vibration from wearing through it, and zip tied it tight.


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074836
10/23/14 05:13 AM
10/23/14 05:13 AM
Struc  Offline OP
Getting the Wheeling Fever
Joined: Apr 2013
Posts: 74
Oconomowoc, WI
Now, because the volume of the 2-piston calipers is so much greater, you really need to replace the master cylinder with the upgraded one as well. Because the stock master cylinder has a brake tee built into it, and the new one doesn't, you'll have to adapt. I got one of these:

[Linked Image]

It's advertised on Ebay and Amazon as a VW Dune Buggy part, but it's just a metric (10mm x 1mm) brake line tee.

Then, with another pair of the Earl's Performance 592032ERL Fittings and a 9" -3an Stainless Line, here is the finished install:

[Linked Image]

[Linked Image]

Properly bleed the brakes (have a VERY large container of brake fluid on hand). Start with the rear, and then the passenger front, then driver's front.

Done!! Enjoy your new braking power!


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074837
10/23/14 10:13 PM
10/23/14 10:13 PM
rxinhed  Offline
Trail Leader
Joined: Feb 2005
Posts: 7,212
Montero Ranch *****
Awesome write-up. The MS backing plates wouldn't work for the Gen I hub? Curious about that. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: rxinhed] #1074838
10/24/14 03:52 AM
10/24/14 03:52 AM
Struc  Offline OP
Getting the Wheeling Fever
Joined: Apr 2013
Posts: 74
Oconomowoc, WI
I believe they do, from other things I have seen on the forums, but I just didn't bother.


Curt Shambeau
87 Mitsubishi Montero SWB (Turbo G64b wideblock conversion soon)
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1074839
10/27/14 11:44 AM
10/27/14 11:44 AM
JARED  Offline
Wheeler
Joined: Jul 2003
Posts: 156
Huntersville, NC
Great write up - this should be a sticky; looking forward to getting this done myself shortly


Gone: '88 2.6 SWB ; '87 2.6 SWB
Current: '90 SWB V6 5Spd
Re: Gen1 Montero SWB 4-cylinder front brake swap [Re: Struc] #1104947
04/10/19 09:46 AM
04/10/19 09:46 AM
O
OConnor  Offline
Need a Spot
Joined: Feb 2016
Posts: 8
VA Beach, VA
Great write up, used your directions for my 91 LWB brake conversion.

Page 2 of 2 1 2

Moderated by  Macka, Mudraider, off-roader, PajEvo, rxinhed 

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