Mitsubishi Outlander XL. Manual - part 602

Q:Is the grease amount low?

YES:

 Apply grease. Then go to Step 7.

NO:

 Go to Step 4.

STEP 4. Check the parking brake pull amount.
Refer to GROUP 36, On-vehicle Service - Parking Brake lever
Stroke Check and Adjustment P.36-11.

Q:Is there a fault?

YES:

 Adjust it. Then go to Step 7.

NO:

 Go to Step 5.

STEP 5. Check port for clogging.

Q:Is the port clogged?

YES:

 Repair it. Then go to Step 7.

NO:

 Go to Step 6.

STEP 6. Check disc brake pistons for sticking.
Depress  the  brake  pedal,  then  release.  Confirm  each  wheel
spins freely.

Q:Does any wheel stick?

YES:

 Inspect that brake assembly. Then go to Step 7.

NO:

 Go to Step 7.

STEP 7. 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 5: Scraping or Grinding Noise when Brakes are Applied

M13501000143USA0000010000

DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for metal-
to-metal condition.

Q:Is any metal-to-metal contact evident?

YES:

 Repair or replace the components. Then go to Step

6.

NO:

 Go to Step 2.

STEP 2. Check for interference between the caliper and
wheel.

Q:Is there any interference?

YES:

 Repair or replace the part. Then go to Step 6.

NO:

 Go to Step 3.

BASIC BRAKE SYSTEM

35A-9

BASIC BRAKE SYSTEM DIAGNOSIS

STEP 3. Check for interference between the dust cover and
brake disc.

ZC6032170000

<Front>

<Rear>

Brake disc

Dust cover

Q:Is there any interference?

YES:

 Repair or replace the part. Then go to Step 6.

NO:

 Go to Step 4.

STEP 4. Check the brake drums or discs for cracks.

Q:Are there cracks?

YES:

 Repair or replace the part. Then go to Step 6.

NO:

 Go to Step 5.

STEP 5. Check for bent backing plate(s).

ZC6030890002

Backing plate

<Rear>

Q:Is (Are) the backing plate(s) bent?

YES:

 Repair or replace the part. 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 6: Squealing, Groaning or Chattering Noise when Brakes
are Applied

M13501000144USA0000010000

DIAGNOSIS

STEP 1. Check the brake disc and pads for wear
or cutting.

Q:Is there wear or cutting?

YES:

 Repair or replace the part. Then go to

Step 4.

NO:

 Go to Step 2.

STEP 2. Check the calipers for rust.

Q:Is there any rust?

YES:

 Remove the rust. Then go to Step 4.

NO:

 Go to Step 3.

STEP 3. Adjust the brake pedal.
Refer to P.35A-14.

Q:Is the brake pedal adjusted correctly?

35A-10

BASIC BRAKE SYSTEM

BASIC BRAKE SYSTEM DIAGNOSIS

YES:

 Go to Step 4.

NO:

 Adjust the brake pedal. Then go to Step 4.

STEP 4. 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 7: Squealing Noise when Brakes are not Applied

M13501000145USA0000010000

DIAGNOSIS

STEP 1. Check whether the backing plate is bent or loose
and interfering with the drum.

Q:Is there a fault?

YES:

 Replace the part. Then go to Step 9.

NO:

 Go to Step 2.

STEP 2. Check whether the drum is damaged due to
interference with the backing plate or shoe.

Q:Is there any damage?

YES:

 Replace the part. Then go to Step 9.

NO:

 Go to Step 3.

STEP 3. Check the brake drum for wear and the shoe spring
for damage.

Q:Is there any wear or damage?

YES:

 Replace the part. Then go to Step 9.

NO:

 Go to Step 4.

STEP 4. Check the brake discs for rust.

Q:Are the brake discs rusted?

YES:

 Remove the rust by using sand paper. If still

rusted, turn the rotors with an on-the-car brake lathe.
Then go to Step 9.

NO:

 Go to Step 5.

STEP 5. Check the brake pads for correct installation.

Q:Are the pads installed incorrectly?

YES:

 Repair the pads. Then go to Step 9.

NO:

 Go to Step 6.

STEP 6. Check the calipers for correct installation.

Q:Are the calipers installed incorrectly?

YES:

 Repair the calipers. Then go to Step 9.

NO:

 Go to Step 7.

STEP 7. Check the wheel bearings for end play.

(1)

Remove the brake discs.

BASIC BRAKE SYSTEM

35A-11

BASIC BRAKE SYSTEM DIAGNOSIS

ZC6010220000

<Front>

<Rear>

(2)

Place a dial gauge as shown, and measure the end play while
moving the hub in the axial direction.

Limit: 0.05 mm (0.002 inch)

Q:Does the measured end play exceed the limit?

YES:

 Replace the faulty hub assembly. Then go to Step 9.

NO:

 Go to Step 8.

STEP 8. Adjust the brake pedal.
Refer to P.35A-14.

Q:Is the brake pedal adjusted correctly?

YES:

 Go to Step 9.

NO:

 Adjust the brake pedal. Then go to Step 9.

STEP 9. 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 8: Groaning, Clicking or Rattling Noise when Brakes are not
Applied.

M13501000146USA0000010000

DIAGNOSIS

STEP 1. Check whether foreign material has entered the
wheel covers.

Q:Is there any foreign material?

YES:

 Remove it. Then go to Step 5.

NO:

 Go to Step 2.

35A-12

BASIC BRAKE SYSTEM

BASIC BRAKE SYSTEM DIAGNOSIS