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Mitsubishi Outlander Front Brake Pads Replacement Guide
How to change the front disc brake pads on a 3rd generation 2014 to 2021 Mitsubishi Outlander SUV.

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2020 Outlander SEL
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Slightly Loosen Lug Nuts
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Raise Front of SUV
This automotive maintenance tutorial was specifically written to assist owners of the third generation (2014, 2015, 2016, 2017, 2018, 2019, 2020 & 2021) Mitsubishi Outlander SUV in changing the front disc brake pads. (Plus instructions for replacing the rotors if necessary.)

Owners of other Mitsubishi vehicles such as the Outlander Sport, Eclipse Cross, Mirage, Mirage G4, Lancer, ASX, Montero Sport, Pajero, Xpander, Strada and RVR may also find these DIY instructions to be helpful.

A few sets of compatible replacement front brake pads with their part numbers are as follows: Bosch BC866, Power Stop 17-866, Wagner QC866, Goodyear GYD866 and Akebono ACT866A.

Please double check the correct part numbers for your vehicle by using the Amazon Part Finder website. The compatible part numbers may vary depending on your SUV's model year, trim level, drive type (AWD or FWD), braking system (single piston calipers or dual piston calipers) and your region of the world.

The tools and other items needed to complete this procedure include a lug nut wrench, a floor jack, two jack stands, a 14mm socket with a 3/8" drive ratchet, an "F" clamp and a tube of brake parts lubricant grease.

The first few steps are to drive the SUV on to a level surface, turn off the ignition, shift the transmission into "P" (Park) and engage the emergency / parking brake.

Place wheel chocks on both sides of the rear tires to help prevent the vehicle from moving.

Slightly loosen the five lug nuts on the front wheel by turning them about 1/4 to 1/2 of a turn in the counterclockwise direction with the tire iron.

Carefully raise the front of the SUV with the floor jack and securely support it with at least two jack stands.

I prefer to only work on one side of the vehicle at a time to keep three tires on the ground for extra safety.



 

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Using 21mm Socket
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Spin Off Five Lug Nuts
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5 Lug Nuts Removed
Spin off the five lug nuts in the counterclockwise direction with the lug nut wrench.

I used a 21mm socket attached to a 1/2" drive breaker bar.

Set the 5 lug nuts aside in a safe place.

Carefully remove the front wheel to reveal the rotor, bracket, caliper and suspension.

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Rotor, Bracket, Caliper
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Loosen Top Caliper Bolt
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Loosen Bottom Bolt
Loosen the top caliper bolt by turning it in the clockwise direction (as seen from the outside of the vehicle) with the 14mm socket and a 3/8" drive ratchet.

Then loosen the bottom caliper bolt by also turning it in the clockwise direction (when viewed from the outside of the SUV) with the 14mm socket and a 3/8" drive ratchet.

There are green arrows on the two pictures above indicating the direction to turn the ratchet to loosen the bolts.

Note - If you were to slide under the SUV and look at the back side of the caliper, you would loosen the caliper bolts in the normal counterclockwise ("lefty loosey") direction. I do not recommend working under the vehicle while changing the brake pads for safety reasons. Since we are looking at the outer face of the caliper, the orientation of the bolts is reversed and they are loosened in the "opposite" clockwise direction from this perspective.

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Spin Out Bottom Bolt
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Top Bolt / Slide Pin
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Pull Off Front Caliper
The two caliper bolts also act as the caliper slide pins (also known as guide pins or slider bolts)..

Spin out the two caliper bolts / slide pins and set them aside in a safe place.

Carefully pull the caliper out of the bracket and off the old pads.

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Rest Caliper On Rotor
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Wear Bar - Top Inner Pad
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Remove Old Outer Pad
Try to avoid pulling, stressing, kinking or bending the rubber brake fluid hose.

Carefully rest the caliper on the rotor or suspend it from the suspension with a bungee cord or some twine.

This 2020 Outlander SEL is equipped with the 1 piston (single piston) front calipers. If your Outlander has the two piston (dual piston) front calipers, the procedure will be slightly different and the part numbers may change.

Pull the old inner and outer brake pads out of the bracket.

Make a mental note of where the wear indicator bar or "squeal bar" is located on the old brake pads.

On this 2020 Outlander SEL, the wear indicator bar was situated at the top of the old inner pad.

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Pad Abutment Clips
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Replace Anti-Rattle Clips
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Attach "F" Clamp
If your new set of front pads includes a bag of replacement brake hardware, pull the old pad abutment clips (or "anti-rattle" clips) out of the top and bottom of the bracket.

Clean off the rotor, lug studs, bracket and rotor with brake parts cleaner spray.

Try to avoid breathing in the brake cleaner spray or the brake dust since they may be carcinogenic (cancer causing).

Apply a thin layer of brake parts lubricant grease to the top and bottom of the new pad abutment clips.

Push the new pad abutment clips into the top and bottom of the bracket.

Avoid getting grease on to the friction surface of the rotor.

Attach the "F" clamp to the caliper and use the back of an old brake pad to evenly distribute the pressure across the piston.

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Right Rear Engine Bay
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Brake Fluid Reservoir Cap
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Compress Caliper Piston
Move to the right rear area of the engine bay and locate the brake fluid reservoir.

Remove the cap by twisting it off in the counterclockwise direction.

Set the reservoir cap aside in a safe place.

Removing the cap will allow the brake fluid to more easily travel back through the line when you compress the caliper piston.

Slowly turn the "F" clamp handle in the clockwise direction to retract back the caliper piston.

Continue compressing the caliper piston until it is just about flush with the rubber dust boot that surrounds it.

Make sure that the piston is going straight back in and not at an angle. Try to avoid pinching or otherwise damaging the rubber dust boot that surrounds the piston.

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Replace Brake Fluid Cap
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Install New Outer Pad
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Wear Bar - Top Inner Pad
Once you are done compressing the caliper piston, replace the reservoir cap by turning it in the clockwise direction.

Since brake fluid is hygroscopic (readily absorbs moisture from the air), the cap shouldn't be left off any longer than absolutely necessary.


Rotor Replacement Instructions

If your Outlander has been exhibiting shuddering, shaking or vibrations in the front end while braking, the OEM rotors might be warped or worn out and should be replaced.

To replace the rotors, remove the two 17mm bolts on the back side of the bracket. Remove the bracket and set the two 17mm bolts aside in a safe place.

Carefully slide the old rotor straight off the lug studs. If you have trouble removing the old rotor due to corrosion or debris, try hitting it with a rubber mallet to loosen the rust.

A few compatible replacement front brake rotors with their part numbers include the following: Wagner BD126509E, DuraGo BR31346 and Centric Parts 121.63067.

Slide the new rotor over the lug studs and against the wheel hub.

Lower the bracket back into place and spin in the two 17mm bolts. Tighten the two caliper bracket bolts until they are snug.

If you have a torque wrench, the 2016 Outlander service manual has a torque specification of 100 N*m +/- 10 N*m or about 73.75 lb-ft for the front caliper bracket bolts. The range in lb-ft would be 66.38 lb-ft (90 N*M) to 81.13 lb-ft (110 N*m).


Orientate the wear indicator bar at the top of the inner brake pad.

Install the new outer and inner brake pads into the bracket.

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Push Pads Against Rotor
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Lower Caliper Over Pads
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Spin In Upper Bolt
Push the two pads together until they are flush against the rotor.

Carefully lower the caliper over the new pads and into the bracket.

Line up the bolts holes in the caliper with their corresponding holes in the bracket.

Apply a thin layer of brake parts lubricant grease to the smooth part of the caliper slide pins.

Avoid getting grease on to the threads of the caliper bolts.

Spin in the upper and lower caliper bolts a few turns by hand to make sure they don't become cross threaded.

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Spin Bottom Bolt
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Tighten Lower Bolt
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Tighten Upper Bolt
Tighten the bolts in the counterclockwise direction (as seen from the outside of the vehicle) with the 14mm socket and a 3/8" drive ratchet until they are snug.

If you have a torque wrench, the shop manual for the 2016 Outlander has a torque specification of 44 N*m +/- 5 N*m or about 32.45 lb-ft +/- 3.68 lb-ft for tightening the front caliper bolts / slider pins.

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Rubber Valve Cap
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Brake Fluid Bleeder Valve
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Brake Pads Replaced

If your brake pedal has been feeling soft or spongy, the brake fluid may be contaminated with water or the brake lines may contain a few air bubbles.

It would be best to bleed the brake lines at this time in order to flush out the old fluid and replace it with either some new DOT 3 or DOT 4 brake fluid.

For more on this topic, check out my Brake Line Fluid Bleeding With An Assistant DIY Guide or alternatively the Brake Line Fluid Bleeding With A Power Bleeder Guide.

The brake fluid bleeder valve is located underneath a rubber cap on the back side of the caliper just below the top caliper bolt.

Double check that the caliper bolts are tight before moving on to the next steps.

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Replace Front Wheel
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Spin On Five Lug Nuts
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Slightly Tighten Lug Nuts
Push the front wheel back into place over the five lug studs.

Spin on the five lug nuts a few turns by hand in the clockwise direction to make sure they don't become cross threaded.

Slightly tighten the lug nuts with the tire iron in a "star" or "criss cross" pattern.

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Lower Car From Stands
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Torque Lug Nuts
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Front Brake Job Done

Carefully lower the vehicle from the jack stands by using the floor jack.

Continue progressively tightening the lug nuts in the clockwise direction in a "criss cross" or "star" pattern to about 1/4 to 1/3 turn past hand tight or 80 lb-ft of torque.

It would be best to use a torque wrench or an electric impact wrench with a torque stick to make sure that the lug nuts are properly tightened to the owner's manual specification of 65 to 80 lb-ft (or 88 to 108 N*m).

Sit in the driver's seat of the car and firmly pump the brake pedal a few times to restore the brake line pressure.

Check the brake fluid in the reservoir and verify that it is at the proper level. If it is low, pour in some fresh DOT 3 or DOT 4 brake fluid from a new bottle until it reaches the "MAX" (maximum) line.

To break in your new front brake pads, just drive normally for the first few hundred miles while trying to avoid any hard or "panic" stops which might glaze over the new pads and cause them to become noisy and/or not perform as well.

It's also a good idea to regularly check your driveway, garage or parking spot for drops of fresh brake fluid which might indicate a leak, check the brake fluid level in the reservoir and also verify that the lug nuts are still tight.

Be sure to write down the pad change in your vehicle's service records.

Please check out all of the 2014-2021 Mitsubishi Outlander DIY Repair & Maintenance Guides.
 

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