Mitsubishi L200. Manual - part 410

AC809218AB

Brake booster

Master cylinder

Front disc brake

<Vehicles without ABS>

<2WD (High rider), 4WD>

LSPV

Rear drum brake

Brake booster

Master cylinder

Front disc brake

<Vehicles with ABS>

Rear drum brake

Hydraulic unit

SERVICE SPECIFICATIONS

BASIC BRAKE

35A-4

SERVICE SPECIFICATIONS

M1351000302257

Item

Standard 
value

Limit

Brake pedal height mm

178.3 

− 181.3 −

Brake pedal free play mm

3 

− 8

−

Brake pedal to floor board clearance mm

75 or more

−

SERVICE SPECIFICATIONS

BASIC BRAKE

35A-5

Load sensing proportioning valve 
(LSPV) output fluid pressure MPa

2WD (except 
High rider)

Spring 
length: 
193.2 mm

Front disc brake 
caliper output fluid 
pressure: 8.12 
MPa

4.98

−

Front disc brake 
caliper output fluid 
pressure: 17.64 
MPa

6.25 

− 7.53

−

Spring 
length: 
223.0 mm

Front disc brake 
caliper output fluid 
pressure: 13.52 
MPa

10.38

−

2WD (High 
rider)

Spring 
length: 
168.8 mm

Front disc brake 
caliper output fluid 
pressure: 5.72 
MPa

2.58

−

Front disc brake 
caliper output fluid 
pressure: 17.64 
MPa

4.33 

− 5.61

−

Spring 
length: 
213.5 mm

Front disc brake 
caliper output fluid 
pressure: 12.02 
MPa

8.88

−

2WD (High 
rider)-Heavy 
duty rear 
suspension

Spring 
length: 
169.0 mm

Front disc brake 
caliper output fluid 
pressure: 4.96 
MPa

1.82

−

Front disc brake 
caliper output fluid 
pressure: 17.64 
MPa

3.72 

− 5.00

−

Spring 
length: 
194.1 mm

Front disc brake 
caliper output fluid 
pressure: 11.52 
MPa

8.38

−

4WD

Spring 
length: 
168.2 mm

Front disc brake 
caliper output fluid 
pressure: 5.92 
MPa

2.78

−

Front disc brake 
caliper output fluid 
pressure: 17.64 
MPa

4.49 

− 5.77

−

Spring 
length: 
213.6 mm

Front disc brake 
caliper output fluid 
pressure: 12.32 
MPa

9.18

−

Item

Standard 
value

Limit

LUBRICANTS

BASIC BRAKE

35A-6

LUBRICANTS

M1351000401529

Item

Specified lubricant

Brake fluid

DOT3 or DOT4

Pin

Repair kit grease (Colour: Translucent red), 
Niglube RX-2 or equivalent

Pin boot inner surface
Piston boot mounting grooves

Repair kit grease

Piston boot inner surface
Rear brake shoe and backing plate 
contact surface

2WD (except High rider) Hyrex No.2 or equivalent
2WD (High rider), 4WD Solvest 842M or Molycort 44MA or equivalent

Rear brake shoe and adjuster 
lever contact surface

2WD (except High rider) Hyrex No.2 or equivalent
2WD (High rider), 4WD Cosmo rubber grease or equivalent

Rear brake shoe and auto adjuster 
assembly contact surface

2WD (except High rider) Hyrex No.2 or equivalent
2WD (High rider), 4WD Cosmo rubber grease or equivalent

Auto adjuster assembly

2WD (except High rider) Hyrex No.2 or equivalent
2WD (High rider), 4WD Cosmo rubber grease or equivalent

Wheel cylinder boot

2WD (except High rider) Repair kit grease, Hyrex No.2 or equivalent
2WD (High rider), 4WD Repair kit grease

Load sensing proportioning valve 
(LSPV) spring length mm

2WD (except High rider)

188 

− 192

−

2WD (High rider), 4WD

Vehicles with rear 
body

165 

− 169

−

Vehicles without 
rear body

161 

− 165

−

Front disc 
brake

Disc brake pad thickness mm

9.5

1.5

Disc brake disc thickness mm

28.0

26.4

Disc brake disc run-out mm

−

0.06

Disc brake drags 
force N

2WD (except High rider)

69 or less

−

2WD (High rider), 4WD

56 or less

−

Rear drum 
brake

Drum brake lining 
thickness mm

2WD (except High rider)

4.7

1.0

2WD (High rider), 4WD

5.0

1.0

Rear drum inside 
diameter mm

2WD (except High rider)

254

256

2WD (High rider), 4WD

295

297

Brake booster push rod protruding 
length mm (When applying 
negative pressure of 66.7 kPa to 
the brake booster)

Vehicles without ASTC

10.0 

− 10.1

−

Vehicles with ASTC

6.6 

− 6.9

−

Item

Standard 
value

Limit

SPECIAL TOOLS

BASIC BRAKE

35A-7

SPECIAL TOOLS

M1351000600780

Tool

Tool number

Name

Use

MB991568

Push rod adjusting 
socket

Adjustment of the brake booster 
push rod protrusion amount

MB990964

A

B

MB990964
A: MB990520
B: MB990621 <2WD (High 
rider), 4WD>, MB990623 
<2WD (except High rider)> 

Brake tool set
A: Disc brake 
piston expander
B: Installer

• Pushing-in of the disc brake 

piston

• Installation of the drum brake 

wheel cylinder piston cup

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND 
ADJUSTMENT

M1351000900770

CAUTION

Do not apply grease or lubricant to the switch 
and the switch installation section to avoid mal-
function of the switch. In addition, do not use 
gloves which have grease on them.

BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc. under the brake pedal.

AC502907AB

A

B

Silencer

Melting sheets

2. Pierce a needle or similar material to the silencer 

and melting sheets, and measure the thickness of 
"A" shown in the figure.

3. Measure the distance between the silencer and 

brake pedal "B" shown in the figure.

4. Check that the total value of "A" and "B" 

measured in the previous items 2 and 3 is within 
the standard value.

Standard value (A + B): 178.3 

− 181.3 mm

[From the surface of dash panel to the face 
of pedal pad]

5. If the brake pedal height is not within the standard 

value, follow the procedure below.
(1) Disconnect the stop lamp switch connector, 

loosen the lock nut, and move the stop lamp 
switch to a position where it dose not contact 
the brake pedal arm.

ACX01815AE

Pedal down

Pedal up

21 ± 3 N·m

(2) Adjust the brake pedal height by turning the 

operating rod with pliers (with the operating 
rod lock nut loosen).