Mitsubishi Lancer Evolution X. Manual - part 124

35A-1

GROUP 35A

BASIC BRAKE 

SYSTEM

CONTENTS

GENERAL INFORMATION . . . . . . . .

35A-2

GENERAL SPECIFICATIONS . . . . . .

35A-3

SERVICE SPECIFICATIONS. . . . . . .

35A-3

LUBRICANTS  . . . . . . . . . . . . . . . . . .

35A-4

BASIC BRAKE SYSTEM DIAGNOSIS

35A-4

INTRODUCTION TO BASIC BRAKE SYSTEM 
DIAGNOSIS  . . . . . . . . . . . . . . . . . . . . . . . . 

35A-4

BASIC BRAKE SYSTEM DIAGNOSTIC 
TROUBLESHOOTING STRATEGY . . . . . . 

35A-4

SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 

35A-4

SYMPTOM PROCEDURES . . . . . . . . . . . . 

35A-5

SPECIAL TOOLS. . . . . . . . . . . . . . . .

35A-12

ON-VEHICLE SERVICE. . . . . . . . . . .

35A-12

BRAKE PEDAL CHECK AND  
ADJUSTMENT  . . . . . . . . . . . . . . . . . . . . . . 

35A-12

BRAKE BOOSTER OPERATION CHECK . 

35A-15

CHECK VALVE OPERATION CHECK . . . . 

35A-16

BLEEDING  . . . . . . . . . . . . . . . . . . . . . . . . . 

35A-16

BRAKE FLUID LEVEL SWITCH CHECK . . 

35A-17

BRAKE PAD CHECK  . . . . . . . . . . . . . . . . . 

35A-18

BRAKE PAD REPLACEMENT  . . . . . . . . . . 

35A-18

DISK BRAKE ROTOR CHECK . . . . . . . . . . 

35A-21

BRAKE DRAG FORCE CHECK . . . . . . . . . 

35A-23

BRAKE PEDAL. . . . . . . . . . . . . . . . . .

35A-24

REMOVAL AND INSTALLATION  . . . . . . . . 

35A-24

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 

35A-25

STOPLIGHT SWITCH CHECK . . . . . . . . . . 

35A-25

BRAKE PEDAL DISTORTION CHECK . . . . 

35A-26

MASTER CYLINDER ASSEMBLY AND 
BRAKE BOOSTER ASSEMBLY  . . . .

35A-26

REMOVAL AND INSTALLATION  . . . . . . . . 

35A-26

FRONT DISC BRAKE ASSEMBLY . .

35A-30

REMOVAL AND INSTALLATION  . . . . . . . . 

35A-30

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 

35A-31

DISASSEMBLY AND ASSEMBLY  . . . . . . . 

35A-32

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 

35A-34

REAR DISC BRAKE ASSEMBLY  . . .

35A-35

REMOVAL AND INSTALLATION  . . . . . . . . 

35A-35

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 

35A-36

DISASSEMBLY AND ASSEMBLY  . . . . . . . 

35A-37

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 

35A-39

GENERAL INFORMATION

TSB Revision

BASIC BRAKE SYSTEM

35A-2

GENERAL INFORMATION

M1351000101119

The brake system has high reliability and durability, 
and provides an exceptional braking performance.

FEATURES

.

IMPROVED BRAKING PERFORMANCE

• In addition to the 10-inch through bolt type single 

brake booster, the small and long stroke-type 
master cylinder is adopted to provide rigidity, to 
reduce weight, and to secure the assist force.

• Brembo™ 18-inch 4-pot front ventilated disk 

brakes and Brembo™ 17-inch 2-pot rear venti-

lated disk brakes are adopted to provide stable 
braking force and improved braking feel.

• To the front, two-piece structure brake disk is 

installed. <GSR: Option, MR: Standard>

.

IMPROVED STABILITY

• Front- and rear-wheel X-type brake line layout is 

used.

• The brake pedal retreat suppression mechanism 

that suppresses the retraction of brake pedal sur-
face upon a frontal collision is adopted.

• To the front brake and rear brake, the brake pads 

with audible wear indicator are adopted which 
warn the driver of the wear limit.

CONSTRUCTION DIAGRAM

AC708805AB

Brake booster

Master cylinder

Front disc brake

Reserve tank

Rear disc brake

Brake pedal

Hydraulic unit

GENERAL SPECIFICATIONS

TSB Revision

BASIC BRAKE SYSTEM

35A-3

GENERAL SPECIFICATIONS

M1351000200599

SERVICE SPECIFICATIONS

M1351000301403

Item

Specification

Master 
cylinder

Type

Tandem type

I.D. mm (in)

23.81 (0.94)

Brake 
booster

Type

Vacuum type, single

Effective dia. of power cylinder mm (in)

252 (10)

Boosting ratio

5.5 {Pedal depression force: 663 N (149 lb)}

Front brakes Type (Disk brake nomenclature)

Brembo™ 4-opposed-piston ventilated disk 

(V8-Z4046)

Brake disk effective dia ×  thickness mm (in) 294 ×  32 (11.6 ×  1.3)
Cylinder I.D. mm (in) [Number of pistons]

40.0 (1.58) [2], 46.0 (1.81) [2]

Brake pad thickness mm (in)

9.85 (0.39)

Clearance adjustment

Automatic adjustment

Rear brakes Type (Disk brake nomenclature)

Brembo™ 2-opposed-piston ventilated disk 

(V7-X40)

Brake disk effective dia ×  thickness mm (in) 278 ×  22 (10.9 ×  0.9)
Cylinder I.D. mm (in) [Number of pistons]

40.0 (1.58) [2]

Brake pad thickness mm (in)

9.0 (0.35)

Clearance adjustment

Automatic adjustment

Brake fluid

DOT3 or DOT4

Item

Standard value

Limit

Brake pedal height mm (in)

219.8 − 227.8 (8.7 − 9.0)

−

Dimension from the brake booster stud bolt end to the clevis 
hole center mm (in)

74 (2.91)

−

Brake pedal free play mm (in)

3 − 8 (0.12 − 0.31)

−

Pedal-to-floor clearance when brake pedal is depressed mm (in) 

[Pedal depression force: approx. 500 N]

85 (3.35) or more

−

Front disk brake

Brake pad thickness mm (in)

9.85 (0.39)

2.0 (0.08)

Brake disk thickness mm (in)

32.0 (1.26)

30.0 (1.18)

Brake disk run-out mm (in)

−

0.06 (0.0024)

Brake drag force N (lb)

68 (15.3) or less

−

Rear disk brake

Brake pad thickness mm (in)

9.0 (0.35)

2.0 (0.08)

Brake disk thickness mm (in)

22.0 (0.87)

20.0 (0.79)

Brake disk run-out mm (in)

−

0.08 (0.0032)

Brake drag force N (lb)

68 (15.3) or less

−

Brake pedal distortion mm (in)

M/T

240 − 246 (9.4 − 9.7)

−

TC-SST

242 − 248 (9.5 − 9.8)

−

LUBRICANTS

TSB Revision

BASIC BRAKE SYSTEM

35A-4

LUBRICANTS

M1351000401002

BASIC BRAKE SYSTEM DIAGNOSIS

INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS

M1351009700405

Hydraulic brakes are composed of the brake pedal, 
master cylinder, brake booster and disk brakes. Mal-
functions such as insufficient braking power or the 
generation of noise may occur due to wear, damage 
or incorrect adjustment of these components.

BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1351009800383

Use these steps to plan your diagnostic strategy. If 
you follow them carefully, you will be sure that you 
have exhausted most of the possible ways to find a 
basic brake system fault.
1. Gather information from the customer.

2. Verify that the condition described by the 

customer exists.

3. Find the malfunction by following the symptom 

chart.

4. Verify malfunction is eliminated.

SYMPTOM CHART

M1351009900410

Item

Specified lubricant

Quantity

Brake fluid

DOT3 or DOT4

Adequate

Brake pad assembly (between pad and 
shim)

Repair kit grease (Color: Black), Molykote AS880N 
or equivalent

Brake pad assembly (shoulder section)

Repair kit grease (Color: Copper), Molykote 7439 or 
equivalent

Symptom

Inspection 
procedure

Reference page

Vehicle pulls to one side when brakes are applied

1

P.35A-5

Insufficient braking power

2

P.35A-5

Increased pedal stroke (Reduced pedal-to-floor board clearance) 3

P.35A-6

Brake drag

4

P.35A-7

Scraping or grinding noise when brake are applied

5

P.35A-8

Squealing, groaning or chattering noise when brake are applied

6

P.35A-9

Squealing noise when brakes are not applied

7

P.35A-10

Groaning, clicking or rattling noise when brakes are not applied

8

P.35A-11