Mitsubishi Outlander XL. Manual - part 605

ZC6010160000

<Front>

<Rear>

2

4

3

5

5

1

4

1

1

1

5

5

4.

Remove the following parts from the caliper assembly.

(1)

Shim

(2)

Pad assembly front

(3)

Pad & clip assembly rear

(4)

Pad assembly RH, pad & wear indicator assembly LH

(5)

Clip

5.

In order to measure the brake drag force after pad installation,
measure the hub sliding torque with no pad attached.(Refer
to P.35A-28.)

6.

Install the pad and caliper assembly, and check the brake drag
force.(Refer to P.35A-28.)

BRAKE DISC THICKNESS CHECK

M13501000024USA0000010000

1.

Remove any dirt and rust on the brake disc surface.

ZC601020 0000

2.

Measure thickness of the brake disc at the sliding area with
the brake pad at four or more points.

Standard value:
Front 26.0 mm (1.02 inch)
Rear 10.0 mm (0.39 inch)
Minimum limit:
Front 24.4 mm (0.96 inch)
Rear 8.4 mm (0.33 inch)

3.

When any one of the thicknesses is lower than the limit value,
replace both brake discs and pads (right and left) as a set.

BRAKE DISC RUNOUT INSPECTION AND

CORRECTION

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When working on the brake disc such as for replacement,
make sure that the wheel speed detection magnetic encoder
should not collect foreign materials.

1.

Remove the caliper assembly and hold it with a wire.

2.

Temporarily fix the brake disc with the hub nut.

BASIC BRAKE SYSTEM

35A-21

ON-VEHICLE SERVICE

ZC6010210000

3.

Set a dial gauge on the brake disc approximately 5 mm inside
the periphery, and measure the runout of the brake disc.

Limit:

0.06 mm (0.0024 inch) <Front>
0.08 mm (0.0032 inch) <Rear>

ZC6010220000

<Front>

<Rear>

4.

When  the  runout  exceeds  the  limit  value,  correct  the  brake
disc runout in the following procedure.

(1)

Before removing the brake disc, mark the wheel stud on
the side of greater runout and its both sides with a chalk.

(2)

Remove the brake disc. Set a dial gauge as shown in the
figure,  and  measure  looseness  of  the  hub  in  the  axial
direction.

Limit: 0.05 mm (0.0020 inch)

(3)

When the looseness exceeds the limit value, replace the
front or rear hub assembly.

(4)

When  the  looseness  is  within  the  limit  value,  install  the
brake disc after changing the phase between the hub and
the  brake  disc,  then  check  the  runout  of  the  brake  disc
again.

5.

If the runout cannot be corrected by changing the phase of the
brake disc, replace the brake disc.

MASTER CYLINDER FUNCTION CHECK

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1.

Remove the reservoir cap.

2.

While watching the open reservoir from a distance
of 50 cm (20 inches), have an assistant depress the
brake  pedal.  If  there  was  a  stream  of  brake  fluid
rising from the reservoir, proceed to Step 3. If there
was  no  stream  of  brake  fluid  rising  from  the
reservoir, replace the master cylinder.

3.

While watching the open reservoir from a distance
of 50 cm (20 inches), have the assistant release the
brake  pedal.  If  there  was  a  small  amount  of  air
bubbles  rising  through  the  brake  fluid,  master
cylinder function is normal. If there were no bubbles
rising  through  the  brake  fluid,  replace  the  master
cylinder.

BRAKE PEDAL

REMOVAL AND INSTALLATION

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Pre-removal and Post-installation operation
Bottom  Cover  Assembly  (driver's  seat)  Removal  and  Installation  (Refer  to  GROUP  52A  -  Instrument  Panel  Assembly  P.

52A-2).

35A-22

BASIC BRAKE SYSTEM

ON-VEHICLE SERVICE

ZC6018000000

4

3

2

6

5

7

1

8

14 ± 3 N·m 
124 ± 26 in-lb

13 ± 2 N·m 
115 ± 18 in-lb

Removal steps

1.

Harness connector

2.

Stop light switch

3.

Pedal clip

4.

Pedal stopper

>>A<<

5.

Snap pin

Removal steps

6.

Pin assembly

7.

Pedal pad

<<A>>

8.

Brake pedal assembly

REMOVAL SERVICE POINT

<<A>> BRAKE PEDAL ASSEMBLY REMOVAL
From  the  engine  compartment  side,  remove  the  brake  pedal
assembly while pulling the brake booster.

BASIC BRAKE SYSTEM

35A-23

BRAKE PEDAL

INSTALLATION SERVICE POINT

>>A<< SNAP PIN INSTALLATION

ZC6010250000

Snap pin

Front of
vehicle

Brake pedal assembly

1.

Install the snap pin as shown in the figure.

BRAKE PEDAL INSPECTION

CHECK THE STOPLIGHT SWITCH CONTINUITY.

M13501000089USA0000010000

AC102416

ZC501246AA01

4 ± 0.5 mm  
(0.16 ± 0.02 in)

No continuity

Continuity

1.

Connect  a  circuit  tester  (Ωrange)  to  the  stop  light  switch
connector.

2.

When no continuity is detected with the plunger pressed from
the  edge  of  the  outer  case  by  the  dimension  shown  in  the
figure  and  when  continuity  is  detected  with  the  plunger
released, the stoplight switch is in good condition.

35A-24

BASIC BRAKE SYSTEM

BRAKE PEDAL