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According to AEM, your calipers will not fit after installing their relocation bracket due to "casting imperfections" with
Mitsubishi's steering knuckle. With that being said, you will need some sort of grinding tool to perform this installation.
I used a Dremel tool for mine. It is not a big deal, just make sure you have the proper tools.
The AEM front brake kit comes with two gorgeous slotted and cross drilled rotors and two caliper relocation brackets.
Start the installation process by loosening your front lug nuts. Once they are loose, jack the car up high enough so that
the front tires no longer touch the ground once the car is on jack stands. I started on the driver's side, removing that
wheel.
Next, remove the two bolts that hold the caliper to the steering knuckle. The bolts are behind the caliper, one at the
top and one at the bottom.
With those bolts removed, the center part of the caliper can be slid off of the brake pads. If you notice, there is a
letter on the back of each bolts that corresponds with a letter on the back of the caliper. One bolt is specifically
designed to be used as the lower bolt, and the other is the upper bolt. Do not get the mixed up. Now, everyone says not to
balance the caliper somewhere because it will fall eventually and tear the brake lines. Well, I always balance them.
Now remove the two bolts that hold the rest of the caliper to the steering knuckle. Again, there is an upper and lower
bolt.
Slide the caliper and brake pads off of the rotor and set them aside - this is the piece you are going to have to
grind on later. The rotor can be pulled off now, nothing is holding it on. If you have trouble getting it off,
it is most likely rusted to the steering knuckle. Use a rubber faced mallet to tap at the back of the rotor, around
the rim, until it comes off.
Now bolt the caliper relocation bracket to the steering knuckle.
Grind down your stock caliper until it fits. Below is my caliper, showing where I had to grind away material. It will be
on the backside of the caliper, so it will not be visible once installed. I had to grind away a LOT more material on the
passenger side than the driver side.
Now slide the new AEM rotor onto the wheel studs, and bolt the caliper frame to the relocation bracket. The rotor will not fit
with the stock dust shield in place. AEM suggests you bend it, I decided to trim the lip off of it and then bend the rest so that
it fit. Below shows how much material I trimmed off of the two dust shields.
At this point, follow the removal instructions in reverse to put everything back together. I had trouble getting the rotor to
sit flat against the steering knuckle. If the rotor doesnt sit flat, it will scrape against the caliper when it spins. Use
your lug nuts to get the rotor flat. Torque them down until the rotor is sitting flat.
At this point you are more or less done. Bolt your wheels back on, lower the car, and tighten the lug nuts with a torque
wrench. Below are some before and after pics.
Before
After
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