Mitsubishi Lancer Evolution X. Manual - part 127

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-13

(2) Check the removed brake pedal assembly for distortion, 

and replace it when deformed (Refer to 

P.35A-26

).

(3) Install the brake pedal assembly (Refer to 

P.35A-24

).

(4) Measure the brake pedal height again, and make sure 

that it is within the standard value (A+B). 

When the measured value is not within the standard 
value, measure the dimension C in the figure (distance 
from the stud bolt end to the clevis hole center), and 
make sure it is within the standard value (C).

Standard value (C): 74 mm (2.91 inch)

(5) When the measured value is not within the standard 

value (C), replace the brake booster (Refer to 

P.35A-26

).

7. After checking the brake pedal height, install the stoplight 

switch in the following procedure:

(1) Pull and hold the brake pedal by hand. Insert the stoplight 

switch until the stoplight switch body contacts the pedal 
stopper, then turn the switch approximately one eighth of 
a clockwise turn to fix it.

(2) Check that the clearance between the stoplight switch 

and the pedal stopper is as shown in the figure.

(3) Connect the stoplight switch connector.

NOTE: Make sure that the stoplight is not illuminated 
when the brake pedal is not depressed.

8. Check the shift lock mechanism <TC-SST> (Refer to 

GROUP 22C − On-vehicle Service, Shift Lock Mechanism 

Check 

P.22C-402

).

9. Recover the floor carpet under the brake pedal.

.

AC508163AB

C

Clevis

Stud bolt

AC309282 AH

Stoplight 
switch body

Pedal stopper

Pedal stopper

0.5 to 1.5 mm
(0.02 to 0.06 in)

Stoplight switch

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-14

BRAKE PEDAL FREE PLAY CHECK AND 
ADJUSTMENT

1. With the engine stopped, depress the brake pedal 2 or 3 

times to release the vacuum in the brake booster. Then, 
press the brake pedal with your finger and check if the pedal 
stroke until the pedal becomes heavy (play) is within the 
standard value.

Standard value (D): 3 − 8 mm (0.12 − 0.31 inch)

2. When the brake pedal free play is not within the standard 

value, check the brake pedal-to-clevis pin looseness, clevis 
pin-to-booster operating rod looseness, brake pedal height, 
and stoplight switch position, and adjust or replace as 
necessary.

.

BRAKE PEDAL-TO-FLOOR PANEL CLEARANCE 
CHECK AND ADJUSTMENT

1. Turn up the floor carpet or other similar material under the 

brake pedal.

2. Using a needle or similar tools, measure the dimension E 

shown in the figure (from the dash panel pad surface to the 
dash panel).

3. Start the engine, and depress the brake pedal with 

approximately 500 N. Then, measure the dimension F 
shown in the figure (from the center of pedal pad surface to 
the dash panel pad surface).

4. Check that the sum of the dimensions E and F measured in 

Steps 2 and 3 (clearance between the brake pedal and the 
floor panel) is within the standard value.

Standard value (E+F): 85 mm (3.35 inch) or more

5. If the clearance between the brake pedal and the floor panel 

is not within the standard value, check for the air intrusion in 
brake line and the thickness of disk brake pad. Make 
corrections or replace components as necessary.

6. Recover the floor carpet or other similar material under the 

brake pedal.

AC505506AF

D

AC706067AB

E

E + F

F

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-15

BRAKE BOOSTER OPERATION CHECK

M1351001000822

.

INSPECTION WITHOUT USING TESTER

1. Carry out the simplified brake booster operation check in the 

following procedure:

(1) Run the engine for 1 to 2 minutes, and then stop. 

Depress the brake pedal with normal depression force. 
The result is judged as "Good" when the pedal stroke is 
great at the first depression, and becomes smaller as you 
repeat depressing the pedal. If the pedal stroke does not 
change, the result is judged as "No Good."

(2) With the engine stopped, depress the brake pedal 

several times. Keep the brake pedal depressed and start 
the engine. At this time, when the pedal moves down 
slightly, the result is judged as "Good." The result is 
judged as "No Good" if the pedal does not move down.

(3) With the engine running, depress the brake pedal. Stop 

the engine in this condition. The result is judged as 
"Good" when the pedal height does not change for 
approximately 30 seconds. The result is judged as "No 
Good" if the pedal moves up.

2. The brake booster is judged as normal when the results of 

all the above checks are "Good."
When one or more of the above check results are "No 
Good," then the check valve, vacuum hose, or brake booster 
is suspected faulty.

AC000870AC

Good

No good

Once

Second

Third

AC000871AC

When engine
is stopped

When engine
is started

AC000872 AC

Good

No good

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-16

CHECK VALVE OPERATION CHECK

M1351009000815

1. Remove the check valve (Refer to 

P.35A-26

).

CAUTION

Replace the check valve when it is faulty.
2. Using a vacuum pump, check operation of the check valve. 

BLEEDING

M1351001401027

CAUTION

Be sure to use the specified brand and type of brake fluid. 
Avoid mixing with other type of brake fluid.

Brake fluid: DOT3 or DOT4

.

BLEEDING OF BRAKE PIPELINE 

Perform the bleeding in the order shown in the figure.

.

DISK BRAKE BLEEDING

CAUTION

Take care not to contact the parts or tools to the caliper 
because the paint of caliper will be scratched. And if there 
is brake fluid on the caliper, wipe it off quickly.
Connect a vinyl tube to the outer end of the air bleeder screws 
to bleed the circuit of air. Then, connect the vinyl tube to the 
inner end and bleed the circuit of air. Except for these, the con-
ventional procedures shall be followed. After the circuit has 
been bled of air, tighten both air bleeder screws securely.

.

Vacuum pump 
connection

Normal condition

When connected to the 
booster side (1)

Vacuum is generated 
and maintained.

When connected to the 
engine side (2)

No vacuum is generated.

AC508114

Valve

Spring

Intake 
manifold
side

Booster side

(1)

(2)

AB

AC607428AE

1

2

3

4

Front of
vehicle

AC211983AC

Bleeder screws