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Mitsubishi Outlander XL. Manual - part 601

Item

Standard value

Limit

Brake drag force N (lb)

68 (15.3) or less

Rear disc brake

Pad thickness mm (in)

10.0 (0.39)

Minimum 2.0 (0.08)

Brake disc thickness mm (in)

10.0 (0.39)

Minimum 8.4 (0.33)

Brake disc runout mm (in)

0.08 (0.0032)

Brake drag force N (lb)

68 (15.3) or less

Front wheel bearing looseness mm (in)

0.05 (0.0020)

Rear wheel bearing looseness mm (in)

0.05 (0.0020)

Brake pedal distortion mm (in)

250 - 254
(9.8 - 10.0)

LUBRICANTS

M13501000004USA0000010000

Item

Specified lubricant

Quantity

Brake fluid

DOT3 or DOT4

Adequate

Master cylinder body, wheel cylinder body,
piston cup, piston, piston seal
Guide pin, lock pin, pin boot, bushing

Repair kit grease (solid orange)

Boot ring, piston boot

Repair kit grease (translucent red)

BASIC BRAKE SYSTEM DIAGNOSIS

INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS

M13501000097USA0000010000

Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disc brakes.
Malfunctions 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

M13501000098USA0000010000

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.

Gather information from the customer.

Verify that the condition described by the customer
exists.

Find the malfunction by following the symptom
chart.

Verify malfunction is eliminated.

SYMPTOM CHART

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SYMPTOM

INSPECTION
PROCEDURE

REFERENCE
PAGE

Vehicle pulls to one side when brakes are applied

P.35A-6

Insufficient braking power

P.35A-7

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

P.35A-7

Brake drag

P.35A-8

Scraping or grinding noise when brake are applied

P.35A-9

BASIC BRAKE SYSTEM

35A-5

LUBRICANTS

SYMPTOM

INSPECTION
PROCEDURE

REFERENCE
PAGE

Squealing, groaning or chattering noise when brake are applied

P.35A-10

Squealing noise when brakes are not applied

P.35A-11

Groaning, clicking or rattling noise when brakes are not applied

P.35A-12

SYMPTOM PROCEDURES

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

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DIAGNOSIS

STEP 1. Check for oil, water, etc., on the pad
contact surface of all brakes.

Q:Is oil, water, etc., on the pad contact surface?

YES:

Replace the part and determine the source/

cause of foreign material. Then go to Step 5.

NO:

Go to Step 2.

STEP 2. 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.
Remove the lower caliper bolt, then remove caliper
from mount.
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 3.

NO:

Disassemble and inspect the brake assembly

(Front: refer to P.35A-30, Rear: refer to P.
35A-35). Then go to Step 5.

STEP 3. Check brake disc(s) for runout.
Refer to P.35A-21.

Q:Is runout outside of specifications?

YES:

Repair or replace the brake disc(s) as

necessary. Then go to Step 5.

NO:

Go to Step 4.

STEP 4. Check brake discs for correct thickness.
Refer to P.35A-21.

Q:Is the thickness outside of specifications?

YES:

Repair or replace the brake disc(s) as

necessary. Then go to Step 5.

NO:

Perform the brake line bleeding. Then go to

Step 5.

STEP 5. 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 appropriate symptom chart.

35A-6

BASIC BRAKE SYSTEM

BASIC BRAKE SYSTEM DIAGNOSIS

INSPECTION PROCEDURE 2: Insufficient Braking Power

M13501000139USA0000010000

DIAGNOSIS

STEP 1. Check that the specified brake fluid is
used, its level is correct, and no contamination is
found.

Q:Is there a fault?

YES:

Refill or replace with the specified brake

fluid DOT 3 or DOT 4. Bleed the brakes if
necessary (Refer to P.35A-18). Then go to Step
6.

NO:

Go to Step 2.

STEP 2. Check for spongy (not firm) brakes.

(1)

With engine not running, depress the brake pedal
rapidly several times to deplete the booster
vacuum reserve.

(2)

With the brake pedal fully released, depress the
brake pedal slowly until it stops.

(3)

With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and measure
the distance the pedal traveled.

Q:Is the distance greater than 20 mm (0.8 inch)?

YES:

Bleed the brakes to remove air in the

fluid (Refer to P.35A-18). Then go to Step 6.

NO:

Go to Step 3.

STEP 3. Check the brake booster function.
Refer to P.35A-16.

Q:Is there a fault?

YES:

Replace the brake booster. Then go to Step

NO:

Go to Step 4.

STEP 4. Check for pinched or restricted brake
tube or hose.

Q:Is there a pinched or restricted brake tube or

hose?

YES:

Replace that complete section of brake

tube or brake hose. Then go to Step 6.

NO:

Go to Step 5.

STEP 5. Check for oil, water, etc., on the pad
contact surfaces of all brakes.

Q:Is oil, water, etc., on the pad contact surface?

YES:

Replace the part and determine the source/

cause of foreign material. Recheck symptom. Then
go to Step 6.

NO:

The procedure is complete. If condition

persists for vehicles without ABS, go to Step 6.

STEP 6. Recheck symptom.

Q:Is the symptom eliminated?

YES:

The procedure is complete.

NO:

Start over at step 1. If a new symptom

surfaces, refer to the appropriate symptom
chart.

INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board
Clearance)

M13501000140USA0000010000

DIAGNOSIS

STEP 1. Check for spongy (not firm) brakes.

(1)

With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserve.

(2)

With the brake pedal fully released, depress the
brake pedal slowly until it stops.

(3)

With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and measure
the distance the pedal traveled.

Q:Is the distance greater than 20 mm (0.8 inch)?

YES:

Bleed the brakes to remove air in the

fluid (Refer to P.35A-18). Then go to Step 6.

NO:

Go to Step 2.

BASIC BRAKE SYSTEM

35A-7

BASIC BRAKE SYSTEM DIAGNOSIS

STEP 2. Check the pad for wear.
Refer to P.35A-21.

Q:Is the pad thickness outside of specifications?

YES:

Replace the part. Then go to Step 6.

NO:

Go to Step 3.

STEP 3. Check the vacuum hose and check valve
for damage.
Refer to P.35A-18.

Q:Is there a damage?

YES:

Replace the part. Then go to Step 6.

NO:

Go to Step 4.

STEP 4. Check the master cylinder function.
Refer to P.35A-22.

Q:Is there a fault?

YES:

Repair it. Then go to Step 6.

NO:

Go to Step 5.

STEP 5. Check for brake fluid leaks.

Q:Is there a leak?

YES:

Check the connection for looseness,

corrosion, etc. Clean and repair as necessary.
If leaking in any tube or hose section, replace
the complete tube or hose. Then go to Step 6.

NO:

Go to Step 6.

STEP 6. Recheck symptom.

Q:Is the symptom eliminated?

YES:

The procedure is complete.

NO:

Start over at step 1. If a new symptom

surfaces, refer to the symptom chart.

INSPECTION PROCEDURE 4: Brake Drag

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DIAGNOSIS
STEP 1. Check the parking brake operating lever return.

ZC6030890000

Parking brake
operating lever

Q:Is the operation faulty?

YES:

Repair it. Then go to Step 7.

NO:

Go to Step 2.

STEP 2. Check the brake shoe springs for breakage.

ZC6030890001

Shoe
springs

Q:Are the brake shoe springs broken?

YES:

Replace the spring. Then go to Step 7.

NO:

Go to Step 3.

STEP 3. Check the amount of grease at each sliding section.
Refer to GROUP 36, Parking Brake Lining and Drum P.
36-14.

35A-8

BASIC BRAKE SYSTEM

BASIC BRAKE SYSTEM DIAGNOSIS

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