Mitsubishi 380. Manual - part 301

DISC BRAKE ASSEMBLY

BASIC BRAKE SYSTEM

35A-38

<<A>> PISTON BOOT/CALIPER PISTON 
REMOVAL

CAUTION

Blow air little by little to remove the piston. The piston will 
pop out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown. 
Blow compressed air through the brake hose connection hole 
to remove the piston boot and piston.

.

<<B>> PISTON SEAL REMOVAL

CAUTION

Do not use a flat-tipped screwdriver or similar tool to 
remove piston seal. These may damage the inner side of 
the cylinder.
1. Remove the piston seal with your finger tip.

2. Clean piston surface and inner cylinder with alcohol or brake 

fluid DOT 3 or DOT 4.

ASSEMBLY SERVICE POINT

.

>>A<< REAR BRAKE PIN INSTALLATION

Attach a guide pin (with "g" on the bolt head) at the bleeder nip-
ple side of the caliper body and a lock pin (with "l" on the bolt 
head) at the opposite side.

INSPECTION

M1351008300039

• Check the cylinder for wear, damage or rust.

• Check the piston surface for wear, damage or rust.

• Check the caliper body or sleeve for wear.

• Check the pad for damage or adhesion of grease, check the 

backing metal for damage.

.

AC204331

AC204684

DISC BRAKE ASSEMBLY

BASIC BRAKE SYSTEM

35A-39

PAD WEAR CHECK

WARNING

•

Always replace both brake pads on each wheel as 
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which 
may cause unreliable brake operation.

•

If there is significant difference in the thickness of 
the pads on the left and right sides, check the slid-
ing condition of the piston and slide pins.

1. Measure thickness at the thinnest and most worn area of the 

pad.

Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

2. Replace the pad assembly if pad thickness is less than the 

limit value.

ACX00690

SPECIFICATIONS

BASIC BRAKE SYSTEM

35A-40

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

M1351009600390

GENERAL SPECIFICATIONS

M1351000200362

ITEM

SPECIFICATION

Brake line

Brake tube flare nut

15 

± 2 N⋅m 

Brake pedal

Brake booster nut

14 

± 2 N⋅m 

Brake pedal bolt

13 

± 2 N⋅m 

Front disc brake

Brake hose connector bolt

30 

± 4 N⋅m 

Caliper bleeder

12.5 

± 1.5 N⋅m 

Front brake assembly mounting bolt

100 

± 10 N⋅m 

Front brake bolt (guide pin bolt)

36.5 

± 1.5 N⋅m

Master cylinder assembly and brake booster

Brake booster nut

14 

± 2 N⋅m 

Brake master cylinder mounting nut

25 

± 2 N⋅m 

Rear disc brake

Brake hose connector bolt

30 

± 4 N⋅m 

Caliper bleeder

12.5 

± 1.5 N⋅m 

Rear brake assembly mounting bolt

60 

± 5 N⋅m 

Rear brake bolt (guide pin bolt)

36.5 

± 1.5 N⋅m 

ITEM

SPECIFICATION

Master 
cylinder

Type

Tandem type

I.D. mm 

25.4 

Brake 
booster

Type

Vacuum type, tandem

Effective dia. of power 
cylinder mm 

205 + 230 

Boosting ratio

6.5

Rear wheel hydraulic control method

Electronic brake-force distribution (EBD) 

Front brakes

Type

Floating caliper, Aluminium housing, 2 piston, ventilated disc

Disc effective dia 

× thickness 

mm 

296 

× 28.0  

Wheel cylinder I.D. mm 

42.0 x 2

Pad thickness mm 

10.0 

Clearance adjustment

Automatic

SPECIFICATIONS

BASIC BRAKE SYSTEM

35A-41

SERVICE SPECIFICATIONS

M1351000300477

LUBRICANTS

M1351000400429

Rear brakes

Type

Floating caliper, Aluminium housing, 1 piston, ventilated disc

Disc effective dia 

× thickness 

mm 

303 

× 18 

Wheel cylinder I.D. mm 

40.5

Pad thickness mm

10.0 

Clearance adjustment

Automatic

ITEM

SPECIFICATION

ITEM

STANDARD VALUE

LIMIT

Brake pedal height mm 

A/T

168.5 

− 171.5 

−

M/T

169.4 

− 172.4

Brake pedal free play mm 

3 

− 8 

−

Brake pedal to floor board clearance mm 

110 or more

−

Disc brake pad thickness mm 

10.0 

Minimum 2.0 

Disc brake disc thickness 
mm 

Front

28.0 Minimum 

26.4 

Rear

18.0 Minimum 

16.4 

Disc brake disc run-out 
mm 

Front

−

0.1 

Rear

−

0.04 

Disc brake drag force N 

Front

64 or less

−

Rear

54 or less

−

Hub end play mm 

−

0.05 

Brake booster push rod protruding length mm. 
[When applying negative pressure of 66.7 kPa to the 
brake booster]

5.0 

± 0.1

−

ITEM

SPECIFIED LUBRICANT

Brake fluid

DOT3 or DOT4

Piston boot, piston seal

Repair kit grease

Front brake pin, rear brake pin (guide pin)