Mitsubishi L200. Manual - part 413

 

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Mitsubishi L200. Manual - part 413

 

 

ON-VEHICLE SERVICE

BASIC BRAKE

35A-16

CAUTION

AC006226 AE

M12 Flat washer

M12 Flat washer

Insert M12 plain washer and then install the 

adapter as shown before grinding. Failure to 
use the M12 plain washer will cause the brake 
disc to be deformed and ground incorrectly.

• To grind the brake disc, ensure that all the 

nuts (M12 X 1.5) are tightened evenly and in a 
diagonal sequence to the specified torque 
(100 N

m). Failure to use all the nuts 

(M12

×1.5), excessive or uneven tightening 

torque will cause the brake disc to deform or 
judder.

5. If the brake disc run-out exceeds the limit value 

after rephasing, grind the disc while in place on 
the vehicle so that the brake disc run-out is within 
the limit value.
NOTE: If it is suspected that the brake disc thick-
ness will be below the limit value, replace the 
brake disc.Then rephase the brake disc so that 
the minimum brake disc run-out is obtained, or 
grind the disc while in place on the vehicle so that 
its run-out is below the limit value.

BRAKE DRAG FORCE CHECK

M1351017200331

1. Remove the brake pad, shim, shim cover <2WD 

(High rider), 4WD> and clip (Refer to 

P.35A-12

).

AC707502AC

<2WD (except High rider)>

Front of vehicle

AC801409AC

<2WD (High rider), 4WD>

Front of vehicle

2. Using a spring scale, measure the hub sliding 

torque in the forward direction with the brake pad 
assembly, shim, shim cover <2WD (High rider), 
4WD> and clip removed.

3. Install the brake pad assembly, shim, shim cover 

and clip (Refer to 

P.35A-12

).

4. Start the engine, and depress the brake pedal 

lightly two or three times. Then stop the engine. 
(Depressing force : approximately 50 

− 100 N)

5. Turn the brake disc 10 times in the forward 

direction.

6. Using a spring scale, measure the hub sliding 

torque in the forward direction with the brake pad 
assembly, shim, shim cover and clip installed.

7. Obtain the disc brake drag force (difference 

between measured values of item 2 and item 6).

Standard value:

69 N or less <2WD (except High rider)>
56 N or less <2WD (High rider), 4WD>

8. If the brake drag force exceeds the standard 

value, disassemble the front brake assembly to 
check for fouling/rust on the piston sliding section, 
piston seal and piston boot deterioration, and 
confirm whether the pin slide properly (Refer to 

P.35A-30

 <2WD (except High rider)> or 

P.35A-33

 

<2WD (High rider), 4WD>).

ON-VEHICLE SERVICE

BASIC BRAKE

35A-17

BRAKE LINING THICKNESS CHECK

M1351003000691

CAUTION

• Whenever the shoe and lining assembly is 

replaced, replace both RH and LH assemblies 
as a set to prevent the car from pulling to one 
side when braking.

• If there is a significant difference in the thick-

ness of the shoe and lining assemblies on the 
left and right sides, check the sliding condi-
tion of the piston.

1. Remove the brake drum.

ACX00708AB

2. Measure the thickness of the brake lining at the 

area with the worst wear.

Standard value:

4.7 mm <2WD (except High rider)>
5.0 mm <2WD (High rider), 4WD>

Limit: 1.0 mm

3. Replace the shoe and lining assembly if the brake 

lining thickness is less than the limit or if it is not 
worn evenly. For installation procedures for the 
shoe and lining assembly, refer to 

P.35A-37

 

<2WD (except High rider)> or 

P.35A-39

 <2WD 

(High rider), 4WD>.

BRAKE DRUM INSIDE DIAMETER CHECK

M1351003200725

1. Remove the brake drum.

AC000893

2. Measure the inside diameter of the brake drum at 

two or more locations.

Standard value:

254 mm <2WD (except High rider)>
295 mm <2WD (High rider), 4WD>

Limit:

256 mm <2WD (except High rider)>
297 mm <2WD (High rider), 4WD>

3. Replace the brake drums, shoe and lining 

assembly when wear exceeds the limit value or is 
badly imbalanced.

BRAKE LINING AND BRAKE DRUM 
CONTACT CHECK

M1351003100557

1. Remove the brake drum.
2. Remove the shoe and lining assembly [Refer to 

P.35A-37

 <2WD (except High rider)> or 

P.35A-39

 

<2WD (High rider, 4WD)>].

AC000856

3. Chalk the inner surface of the brake drum and rub 

with the shoe and lining assembly.

4. Replace the shoe and lining assembly or brake 

drums if there are any irregular contact areas.
NOTE: Clean off chalk after check.

BRAKE PEDAL

BASIC BRAKE

35A-18

BRAKE PEDAL

REMOVAL AND INSTALLATION

M1351003400688

CAUTION

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

Post-installation Operation
Brake pedal adjustment (Refer to 

P.35A-7

).

AC508344AB

14 ± 3 N·m

6

1

2

3

4

5

7

12 ± 2 N·m

7

<M/T>

<A/T>

8

Removal steps 

1. Stop lamp switch connector 

connection

2. Stop lamp switch
3. Adjuster
4. Pedal stopper
5. Snap pin
6. Pin assembly
7. Pedal pad

>>

A

<< 8. Brake pedal and pedal support 

member

INSTALLATION SERVICE POINT

>>A<< BRAKE PEDAL AND PEDAL SUPPORT 
MEMBER INSTALLATION

AC504313AB

Brake pedal and pedal
support member

a

b

a

Tighten the bolt "a" first, and then tighten the bolt "b."

BRAKE PEDAL

BASIC BRAKE

35A-19

INSPECTION

STOP LAMP SWITCH CHECK

M1351008900451

<VEHICLES WITHOUT CRUISE CONTROL 
SYSTEM>

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.

AC801502AB

No continuity

Continuity

4.0 ± 0.75 mm

Check for continuity between the terminals of the 
switch.

Check 
condition

Terminal 
connector of 
tester

Normal 
condition

At free position 1 

− 2

Continuity 
exists

 

(2 

Ω or less)

Press the 
plunger from the 
edge of the 
outer case by 
the dimension 
shown in the 
figure.

− 2

No continuity

<VEHICLES WITH CRUISE CONTROL SYSTEM>

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.

AC801503AB

No continuity

For stop lamp switch

For cruise control

Continuity

4.0 ± 0.5 mm

Continuity

No continuity

4.5 ± 0.5 mm

Check for continuity between the terminals of the 
switch.

Check 
condition

Terminal 
connector of 
tester

Normal 
condition

At free position 1 

− 2 (for stop 

lamp switch)

Continuity 
exists

 

(2 

Ω or less)

− 4 (for cruise 

control)

No continuity

Press the 
plunger from the 
edge of the 
outer case by 
the dimension 
shown in the 
figure.

− 2 (for stop 

lamp switch)

No continuity

− 4 (for cruise 

control)

Continuity 
exists

 

(2 

Ω or less)

 

 

 

 

 

 

 

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