Content .. 47 48 49 50 ..

Mitsubishi Montero (1998+). Manual - part 49

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Application incorrect includes wrong bulb coating

or color.

(2) - Determine cause and correct prior to repair or

replacement of part.

CALIPER HARDWARE

CALIPER HARDWARE INSPECTION

Condition Code Procedure

Bent ................... A .. Require repair or replacement.

Broken .................. A .. Require repair or replacement.

Corroded, affecting

performance ............ A .. Require repair or replacement.

Dust boots on slider pin

(bolt) missing ......... C ... Require replacement of boots.

Dust boots on slider pin

(bolt) torn ............ A ... Require replacement of boots.

Missing ................. C ............ Require replacement.

Shim bent ............... A ............. ( 1) Require removal

or replacement.

Shim (OE standard)

missing ................ C ........ (2) Require replacement.

Shim out of position .... B ............. ( 1) Require removal

or replacement.

Shim worn ............... A ............. ( 1) Require removal

or replacement.

Slider pin (bolt) bent .. B ... Require replacement of slider

pin or bolt and lubricants.

Slider pin (bolt)

rust-pitted ............ A ... Require replacement of slider

pin or bolt and lubricants.

Slider pin (bolt) worn .. A ... Require replacement of slider

pin or bolt and lubricants.

Threads damaged ......... A .. Require repair or replacement.

Threads stripped (threads

missing) ............... A ............ Require replacement.

Worn, affecting

performance ............ A ............ Require replacement.

(1) - Removal is acceptable if shim is not OE.

(2) - Aftermarket shims may be suggested to reduce noise.

CALIPERS

You are not required to replace or rebuild calipers in axle

sets. However, when replacing or rebuilding a caliper due to the

conditions that follow, you may suggest servicing, rebuilding, or

replacement of the other caliper (on the same axle) for improved

performance and preventive maintenance (for example, the part is close

to the end of its useful life, replacing the caliper may extend pad

life, or contribute to more balanced braking).

CAUTION: When installing loaded calipers, it is required that

friction material be matched in axle sets for consistent

braking characteristics.

CALIPER INSPECTION

Condition Code Procedure

Bleeder port damaged .... A ... Require repair or replacement

of caliper.

Bleeder screw broken off

in caliper ............. A ........... ( 1) Require repair or

replacement of caliper.

Bleeder screw plugged ... A ........... ( 1) Require repair or

replacement of bleeder screw.

Bleeder screw seized .... A ......... ( 2) Require replacement

of caliper.

Casting corroded,

affecting structural

integrity .............. A ............ Require replacement.

Casting damaged, affecting

structural integrity ... A ............ Require replacement.

Dust boot around caliper

torn ................... A ..... Require replacement of dust

boot.

Leaking ................. A .. Require repair or replacement.

Mounting pin threads

damaged ................ A ... Require repair or replacement

of component with damaged

threads.

Mounting pin threads

stripped in caliper

bracket (threads

missing) ............... A ... Require repair or replacement

of caliper bracket.

Mounting pin threads

stripped in steering

knuckle (threads

missing) ............... A ... Require repair or replacement

of steering knuckle.

Mounting pin threads

stripped (threads

missing) ............... A ... Require repair or replacement

of component with stripped

threads.

Parking brake cable

support, lever, or return

spring bent ............ A ... Require replacement of parts.

Parking brake cable

support, lever, or return

spring broken .......... A ... Require replacement of parts.

Parking brake mechanism in

caliper inoperative .... A .. Require repair or replacement.

Piston corroded (pitted

or peeling chrome

plating) ............... B ... Require replacement of piston

and rebuilding or replacement

of caliper.

Piston damaged, affecting

performance ............ B ... Require replacement of piston

and rebuilding or replacement

of caliper.

Piston damaged, not

affecting performance .. .. ........ No service suggested or

required.

Piston finish worn off .. B ... Require replacement of piston

and rebuilding or replacement

of caliper.

Piston sticking ......... A ........... Require rebuilding or

replacement of caliper.

Slide mechanism

sticking ............... A ... Require repair or replacement

of slide mechanism.

(1) - Only required if the hydraulic system must be opened.

(2) - Seized is defined as a bleeder screw that cannot be

removed after a practical attempt at removing. Only

required if the hydraulic system must be opened.

CONTROLLERS

See ELECTRONIC CONTROLLERS.

DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)

DIGITAL RATIO AXLE CONTROLLER AND BUFFER INSPECTION

Condition Code Procedure

Connector broken ........ A .. Require repair or replacement.

Connector (Weatherpack

type) leaking .......... A .. Require repair or replacement.

Connector melted ........ A ........ (1) Require replacement.

Connector missing ....... C ............ Require replacement.

Missing ................. C ............ Require replacement.

Output signal incorrect . B .. Require repair or replacement.

Terminal burned, affecting

performance ............ A .............. ( 2) Require repair

or replacement.

Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement.

Terminal corroded,

affecting performance .. A .. Require repair or replacement.

Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.

Terminal loose, affecting

performance ............ B .. Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Determine cause and correct prior to replacement of part.

(2) - Determine cause and correct prior to repair or

replacement of part.

DISABLE SWITCHES

See SWITCHES.

DRUMS

Determine the need to recondition based upon individual drum

conditions that follow. Friction material replacement does not require

drum reconditioning unless other justifications exist. DO NOT

recondition new drums unless they are being pressed or bolted onto an

existing hub. It is not necessary to replace drums in axle sets.

However, when replacing or reconditioning a drum due to the conditions

that follow, you may suggest reconditioning of the other drum on the

same axle to eliminate uneven braking behavior. Always wash drums

after servicing or before installing.

DRUM INSPECTION

Condition Code Procedure

Balance weight missing .. .. ........ No service suggested or

required.

Bell-mouthed, affecting

performance ............ A ....... Require reconditioning or

replacement.

Cooling fin broken ...... .. ........ No service suggested or

required.

Cracked ................. B ............ Require replacement.

Drum diameter is greater

than OEM "machine to"

specifications but less

than "discard at"

specifications, and the

drum does not require

reconditioning ......... 1 ........ (1) Suggest replacement.

Drum diameter will exceed

OEM "machine to"

specifications after

required

reconditioning ......... B ........ (2) Require replacement.

Hard-spotted ............ 2 ....... Suggest reconditioning or

replacement.

Measured diameter is

greater than OEM discard

specifications ......... B ............ Require replacement.

Out-of-round (runout),

affecting performance .. A ....... Require reconditioning or

replacement.

Out-of-round (runout),

exceeding manufacturer’s

specifications ......... B ....... Require reconditioning or

replacement.

Scored .................. B ....... Require reconditioning or

replacement.

Surface threaded due to

improper machining ..... B ....... Require reconditioning or

replacement.

Tapered, affecting

performance ............ A ....... Require reconditioning or

replacement.

(1) - Only applies to vehicles for which OEM "machine to"

specifications exist. If OEM does not supply "machine to"

specifications, the drum may be worn to discard

specifications.

(2) - If OEM does not supply "machine to" specifications, you

may machine to discard specifications.

ELECTRICAL PUMPS AND MOTORS

Copied fuel pump conditions from engine UIGs & deleted

pulsator from leaking conditions.

ELECTRICAL PUMP AND MOTOR INSPECTION

Content .. 47 48 49 50 ..