Index Mitsubishi Mitsubishi Montero Sport - service repair manual 2004 year

Content .. 767 768 769 770 ..

Mitsubishi Montero Sport (2004+). Manual - part 769

35A-1

GROUP 35A

BASIC BRAKE

SYSTEM

CONTENTS

GENERAL DESCRIPTION. . . . . . . . .

BASIC BRAKE SYSTEM DIAGNOSIS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . .

DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

BRAKE BOOSTER OPERATING CHECK .

CHECK VALVE OPERATION CHECK . . . .

PROPORTIONING VALVE FUNCTION TEST

<VEHICLES WITHOUT ABS> . . . . . . . . . .

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

BRAKE FLUID LEVEL SWITCH CHECK . .

DISC BRAKE PAD CHECK AND
REPLACEMENT . . . . . . . . . . . . . . . . . . . . .

DISC BRAKE ROTOR CHECK. . . . . . . . . .

FRONT BRAKE DISC RUN-OUT CHECK

AND CORRECTION . . . . . . . . . . . . . . . . . .

BRAKE DISC THICKNESS CHECK . . . . . .

BRAKE LINING THICKNESS CHECK . . . .

BRAKE DRUM INSIDE DIAMETER CHECK

BRAKE LINING AND BRAKE DRUM

CONTACT CHECK . . . . . . . . . . . . . . . . . . .

AUTO ADJUSTER FUNCTION CHECK . . .

MASTER CYLINDER FUNCTION CHECK.

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

REMOVAL AND INSTALLATION . . . . . . . .

MASTER CYLINDER ASSEMBLY
AND BRAKE BOOSTER . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . .

DISASSEMBLY AND ASSEMBLY . . . . . . .

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

FRONT DISC BRAKE ASSEMBLY . .

REMOVAL AND INSTALLATION . . . . . . . .

DISASSEMBLY AND ASSEMBLY . . . . . . .

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

REAR DRUM BRAKE. . . . . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . .

WHEEL CYLINDER DISASSEMBLY AND
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

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

PROPORTIONING VALVE . . . . . . . . .

REMOVAL AND INSTALLATION . . . . . . . .

SPECIFICATIONS . . . . . . . . . . . . . . .

FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS . . . . . . . . . .

SERVICE SPECIFICATIONS . . . . . . . . . . .

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

SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION

TSB Revision

BASIC BRAKE SYSTEM

35A-2

GENERAL DESCRIPTION

M1351000100473

The brake system has high reliability and durability
which maintains excellent braking performance and
braking feeling. The main features are as follows:

• A dual type master cylinder is equipped in all

models.

• Tandem type brake booster is used.

• The following type of brake is used.

• Front: Floating caliper, 2-piston, ventilated

disc brakes (V6-W43)

• Rear: Leading-trailing type drum brake

CONFIGURATION DIAGRAM

BASIC BRAKE SYSTEM DIAGNOSIS

INTRODUCTION

M1351009700342

Hydraulic brakes configured of the brake pedal, mas-
ter cylinder, brake booster and drum brakes, are
incorporated. Malfunctions such as insufficient brak-
ing power or the generation of noise may occur due
to wear, damage or incorrect adjustment of these
parts.

DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1351009800338

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.

AC309304

REAR DRUM BRAKE

FRONT DISC BRAKE

FRONT DISC BRAKE

MASTER CYLINDER

BRAKE BOOSTER

REAR DRUM BRAKE

PROPORTIONING VALVE
<VEHICLES WITHOUT ABS>

AB

BASIC BRAKE SYSTEM DIAGNOSIS

TSB Revision

BASIC BRAKE SYSTEM

35A-3

SYMPTOM CHART

M1351009900357

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied.

.

DIAGNOSIS

STEP 1. Check for oil, water, etc., on the pad or lining
contact surface of all brakes.
Q: Is oil, water, etc., on the pad or lining contact surface?

YES : Replace the part and determine and repair

source/cause of foreign material. Then go to Step 8.

NO : Go to Step 2.

STEP 2. Check the lining and brake drum contact.

Put chalk on the inner surface of the brake drum. Rub the lining
against the drum inner surface.
NOTE: Clean off chalk after check.
Q: Does the lining wipe off or smudge the chalk across the

full width of the lining?
YES : Go to Step 3.
NO : Replace the shoe and lining assemblies on both

sides. Then go to Step 8.

STEP 3. Check the auto adjuster function.

Refer to

Q: Is there fault?

YES : Repair it. Then go to Step 8.
NO : Go to Step 4.

SYMPTOM

INSPECTION
PROCEDURE

REFERENCE
PAGE

Vehicle pulls to one side when brakes are applied.

1

Insufficient braking power

2

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

Brake drag

4

Insufficient parking brake function

5

Scraping or grinding noise when brakes are applied

6

Squealing, groaning or chattering noise when brakes are applied

7

Squealing noise when brakes are not applied

8

Groaning, clicking or rattling noise when brakes are not applied

9

AC000856AB

BASIC BRAKE SYSTEM DIAGNOSIS

TSB Revision

BASIC BRAKE SYSTEM

35A-4

STEP 4. Check the brake drum inside diameter.

Refer to

Q: Is the brake drum inside diameter outside of

specifications?
YES : Replace the part. Then go to Step 8.
NO : Go to Step 5.

STEP 5. Check disc brake pistons for smooth operation.
(1) With engine not running, depress the brake pedal rapidly

several times to deplete booster vacuum reserves.

(2) Test each disc brake assembly one at a time.

a. Remove the lower caliper bolt, then remove caliper from

mount.

b. Have an assistant slowly depress the brake pedal.

Confirm piston(s) extend slowly and smoothly with no
jumpiness. Repeat for each disc brake assembly.

Q: Do (does) the piston(s) move correctly?

YES : Go to Step 6.
NO : Disassemble and inspect brake assembly (Refer to

). Then go to Step 8.

STEP 6. Check brake disc(s) for run out.

Refer to

Q: Is runout outside of specifications?

YES : Repair and replace as necessary. Then go to Step 8.
NO : Go to Step 7.

STEP 7. Check brake discs for correct thickness.

Refer to

Q: Is the thickness outside of specifications?

YES : Repair or replace as necessary. Then go to Step 8.
NO : Go to Step 8.

STEP 8. Retest the system.
Q: Is the symptom eliminated?

YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom appears, refer

to the symptom chart

.

Content .. 767 768 769 770 ..