Mitsubishi 35A, 35B, 35C User Manual

35A-1

SERVICE BRAKES

CONTENTS

BASIC BRAKE SYSTEM 35A.........................................

ANTI-SKID BRAKING SYSTEM (ABS) <2WD> 35B......................

ANTI-SKID BRAKING SYSTEM (ABS) <4WD> 35C......................

NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL

35109000159

35A-2

BASIC BRAKE

SYSTEM

CONTENTS

GENERAL INFORMATION 3..................

SERVICE SPECIFICATIONS 4.................

LUBRICANTS 5..............................

SEALANTS 5................................

SPECIAL TOOLS 5..........................

ON-VEHICLE SERVICE 6.....................

Brake Pedal Check and Adjustment 6...........

Stop Lamp Switch Check 7.....................

Brake Booster Operating Test 7.................

Check Valve Operation Check 8.................

Proportioning Valve Function Test 9.............

Brake Fluid Level Sensor Check 9..............

Bleeding 10....................................

35109000302

Disc Brake Pad Check and Replacement 10.....

Disc Brake Rotor Check 12.....................

Brake Lining Thickness Check 14...............

Brake Drum Inside Diameter Check 14..........

Brake Lining and Brake Drum Connection

Check 14......................................

BRAKE PEDAL 15..........................

MASTER CYLINDER AND BRAKE

BOOSTER 16...............................

Master Cylinder 18.............................

DISC BRAKE 19............................

REAR DRUM BRAKE 24....................

Wheel Cylinder 26.............................

PROPORTIONING VALVE 28.................

BASIC BRAKE SYSTEM -

General Information

35A-3

GENERAL INFORMATION

35100010182

The brake system offers high dependability and durability along with improved braking performance and brake sensitivity.

Items Specifications

Master cylinder Type Tandem type (with level sensor)

I.D. mm 23.8

Brake booster Type Vacuum type, single

Effective dia. of power cylinder mm 230

Boosting ratio 6.0

Proportioning valve Type Dual type

Decompression ratio 0.25

Front brakes Type Floating caliper, 1-piston, ventilated disc

Disc effective dia.´thickness mm 256´24

Wheel cylinder I.D. mm 60.3

Pad thickness mm 10.0

Clearance adjustment Automatic

Rear disc brakes Type Floating caliper, 1-piston, solid disc

Disc effective dia.´thickness mm 262´24

Wheel cylinder I.D. mm 34.9

Pad thickness mm 10.0

Clearance adjustment Automatic

Rear drum brakes Type Leading trailing

Drum I.D. mm 203

Wheel cylinder I.D. mm 20.6

Lining thickness mm 4.4

Clearance adjustment Automatic

Brake fluid DOT3 or DOT4

35A-4

BASIC BRAKE SYSTEM -

CONSTRUCTION DIAGRAM

Brake booster

Master cylinder

General Information/ ServiceSpecifications

Rear brake

Proportioningvalve

Front brake

Brake pedal

SERVICE SPECIFICATIONS

Items Standard value Limit Brake pedal height mm 162.8 - 165.8 Brake pedal free play mm 3-8 Brake pedal to floor board clearance mm 90 or more Proportioning valve Split point MPa Sedan 2.94±0.25 -

Wagon 3.43±0.25 -

Output fluid pressure Sedan 4.66±0.39 (9.81) (Input fluid pressure) MPa

Wagon 5.80±0.39 (9.81) -

Output fluid pressure difference between left and right MPa

- 0.39

35100030201

Brake booster push rod protruding length mm 9.65 -9.90 Front disc brake Pad thickness mm 10.0 2.0

Disc thickness mm 24.0 22.4 Disc runout mm - 0.06 Dragforce (tangential forceof wheelmounting

bolts) N

69 or less -

Service Specifications/Lubricants/

BASIC BRAKE SYSTEM -

Items Standard value Limit

Rear disc brake Pad thickness mm 10.0 2.0

Disc thickness mm 10.0 8.4

Disc runout mm - 0.08

Sealants/Special Tools

35A-5

Drag force (tangential force of wheel mounting bolts) N

Rear drum brake Lining thickness mm 4.4 1.0

Drum inside diameter mm 203 205

69 or less -

LUBRICANTS

Items Specified Lubricant

Brake fluid DOT3 or DOT4

Brake piston seal Repair kit grease (orange)

Slide pin boot and slide pin bush inner surfaces

Brake piston boot inner surfaces

Piston boot mounting grooves

Rear brake shoe and backing plate contact surfaces Brake grease SAE J310, NLGI No.1

Shoe assembly and auto adjuster assembly contact surfaces

Shoe and lever assembly and auto adjuster assembly contact surfaces

35100040082

SEALANTS

Items Specified sealant Remarks

Thread part fitting 3M ATD Part No. 8661 or equivalent Semi-drying sealant

V acuum switch

SPECIAL TOOLS

Tool Number Name Use

MB990964 MB990520 MB990619

MB990998 Front hub remover

Brake tool set D Pushing-in of the disc brake piston

D Installation of drum brake wheel cylinder

piston cup

Provisional holding of the wheel bearing

and installer

35100050153

35100060071

35A-6

BASIC BRAKE SYSTEM -

On-vehicle Service

Operating rod

Operating rod lock nut

Pedal down

Pedal up

Lock nut

Stop lamp switch

Lock nut

Outer case

0.5 - 1.0 mm

ON-VEHICLE SERVICE

35100090186

BRAKE PEDAL CHECK AND ADJUSTMENT

BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc under the brake pedal.

2. Measure the brake pedal height as illustrated. If the brake pedal height is not within the standard value, follow the procedure below.

Standard value: 162.8 - 165.8 mm

(1) Disconnect the stop lamp switch connector. (2) Adjust the brake pedal height by turning the operating

rod with pliers (with the operating rod lock nut loosened), until the correct brake pedal height is obtained.

(3) Secure by tightening the lock nut of the operating

rod.

(4) Push the stop lamp switch in the direction of the

pedal stroke until it stops. (The switch will slide if it is pushed firmly.)

(5) Lift up the pedal until the operating rod is fully

extended, and then slide the stop lamp switch back to the required position. Adjust the position of the switch by turning it until the distance shown in the

illustration is correct. (6) Connect the connector of the stop lamp switch. (7) Check that the stop lamp is not illuminated with the

brake pedal unpressed.

3. Return the carpet etc.

BRAKE PEDAL FREE PLAY

With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value range.

BASIC BRAKE SYSTEM -

Standard value: 3–8 mm

If the free play exceeds the standard value, it is probably due to excessive play between the retaining ring bolt and brake pedal arm. Check for excessive clearance and replace faulty parts as required.

CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD

1. Turn back the carpet etc. under the brake pedal.

2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floorboard.

Standard value: 90 mm or more

3. If the clearance is outside the standard value, check for air trapped in the brake line, clearance between the lining and the drum and dragging in the parking brake. Adjust and replace defective parts as required.

On-vehicle Service

35A-7

No continuity

Good No good

Continuity

4mm

4. Return the carpet etc.

STOP LAMP SWITCH CHECK

35100890120

Connect a circuit tester to the stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. The stop lamp switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm from the outer case edge surface, and if there is continuity when it is released.

BRAKE BOOSTER OPERATING TEST

35100100117

For simple checking of the brake booster operation, carry out the following tests:

1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is defective.

35A-8

BASIC BRAKE SYSTEM -

On-vehicle Service

When engine is stopped

When engine is started

2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective.

3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above three tests are okay, the booster performance can be determined as good. If one of the above three tests is not okay at last, the check valve, vacuum hose, or booster will be defective.

Valve

Booster side

Spring

Intake manifold side

CHECK VALVE OPERATION CHECK

35100900151

1. Remove the vacuum hose. (Refer to P.35A-16.)

Caution The check valve should not be removed from the vacuum hose.

2. Check the operation of the check valve by using a vacuum pump.

V acuum pump connection Accept/reject criteria

Connection at the brake booster side (A)

Connection at the intake manifold side (B)

A negative pressure (vacuum) is created and held.

A negative pressure (vacuum) is not created.

Caution If the check valve is defective, replace it as an assembly unit together with the vacuum hose.

BASIC BRAKE SYSTEM -

On-vehicle Service

35A-9

Output pressure

Pressure gauge

Proportioning valve

Split point

Input pressure

PROPORTIONING VALVE FUNCTION TEST

35100110172

1. Connect two pressure gauges, one each to the input side and output side of the proportioning valve, as shown.

2. Bleed the air in the brake line and the pressure gauge.

3. While gradually depressing the brake pedal, make the following measurements and check to be sure that the measured values are within the allowable range.

(1) Output pressure begins to drop relative to input

pressure (split point).

Standard value:

MPa

Sedan Wagon

2.94±0.25 3.43±0.25

(2) Check to be sure that the output fluid pressure is

at the standard value when the pedal depression force is increased so that the input fluid pressure is at the values shown in the table below.

Standard value:

MPa

Sedan Wagon

Output fluid pressure (Input fluid pressure)

4.66±0.39 (9.81)

5.80±0.39 (9.81)

(3) Output pressure difference between left and right

brake lines.

Limit: 0.39 MPa

4. If the measured pressures are not within the permissible ranges, replace the proportioning valve.

BRAKE FLUID LEVEL SENSOR CHECK

35100910123

The brake fluid level sensor is in good condition if there is no continuity when the float surface is above “MIN” and if there is continuity when the float surface is below “MIN”.

35A-10

BASIC BRAKE SYSTEM -

On-vehicle Service

BLEEDING

35100140089

Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid.

Specified brake fluid: DOT3 or DOT4

MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) (1) Fill the reserve tank with brake fluid. (2) Keep the brake pedal depressed. (3) Have another person cover the master cylinder outlet

with a finger.

(4) With the outlet still closed, release the brake pedal. (5) Repeat steps (2)- (4) three or four times to fill the inside

of the master cylinder with brake fluid.

4 (2)

2 (4)

( ): R.H. drive vehicles

When new When worn

Pad

Wear indicator

Brake disc

1 (3)

3 (1)

BRAKE PIPE LINE BLEEDING

Bleed the air in the sequence shown in the figure.

DISC BRAKE PAD CHECK AND REPLACEMENT

NOTE The left side outer brake pad has a wear indicator. The wear indicator contacts the brake disc when the brake pad thickness becomes 2 mm and emit a squealing sound to warn the driver.

35100230014

BASIC BRAKE SYSTEM -

1. Check brake pad thickness through caliper body check port.

Standard value: 10 mm Limit: 2.0 mm

Caution

1. When the limit is exceeded, replace the pads at

both sides, and also the brake pads for the wheels on the opposite side at the same time.

2. If there is a significant difference in the thickness

of the pads on the left and right sides, check the sliding condition of the piston and guide pin.

2. Remove the guide pin. Lift caliper assembly and retain with wires.

Caution Do not wipe off the special grease that is on the guide pin or allow it to contaminate the guide pin.

On-vehicle Service

35A-11

3. Remove the following parts from caliper support. (1) Pad and wear indicator assembly <L.H.>, and pad

assembly <R.H.> (2) Pad assembly (3) Pad liner (4) Outer shim

4. In order to measure the brake drag force after pad installation, measure the rotary-sliding resistance of the hub with the pads removed. (Refer to P.35A-19.)

5. Install the pads and the caliper assembly, and then check the brake drag force. (Refer to P.35A-19.)

35A-12

BASIC BRAKE SYSTEM -

On-vehicle Service

DISC BRAKE ROTOR CHECK

35100290012

Caution When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation.

Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.

Inspection items Remarks

Scratches, rust, saturated lining materials and wear

Run-out or drift Excessive run-out or drift of the discs will increase the pedal depression

Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,

Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or

If the vehicle is not driven for a certain period, the sections of the discs that are not in contact with lining will become rusty, causing noise and shuddering.

If grooves resulting from excessive disc wear and scratches are not removed prior to installing a new pad assembly, there will momentarily be inappropriate contact between the disc and the lining (pad).

resistance due to piston knock-back.

shuddering and surging.

warping.

THICKNESS CHECK

35100240017

1. Using a micrometer, measure disc thickness at eight positions, approximately 45_apart and 10 mm in from the outer edge of the disc.

Brake disc thickness

Standardvalue: 24.0 mm <Front>, 10.0 mm<Rear> Limit: 22.4 mm <Front>, 8.4 mm <Rear>

Thickness variation (at least 8 positions)

The difference between any thickness measurements should not be more than 0.015 mm.

2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the specification, replace the brake disc or turn rotor with on the car type brake lathe (“MAD, DL-8700PF” or equivalent).

BASIC BRAKE SYSTEM -

On-vehicle Service

35A-13

RUN-OUT CHECK

35100250010

1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire.

2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust.

3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.

Limit:

0.06 mm or less <Front>

0.08 mm or less <Rear>

NOTE Tighten the nuts in order to secure the disc to the hub.

RUN-OUT CORRECTION

35100180081

1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, change the phase of the disc and hub, and then measure the run-out again. (1) Before removing the brake disc, chalk both sides

of the wheel stud on the side at which run-out is greatest.

Chalk mark

(2) Remove the brake disc, and then place a dial gauge

as shown in the illustration; then move the hub in the axial direction and measure the play.

Limit: 0.05 mm

If the play is equivalent to or exceeds the limit, disassemble the hub knuckle and check each part.

(3) If the play does not exceed th e limit specification,

install the brake disc at a position 180_ away from the chalk mark, and then check the run-out of the brake disc once again.

2. If the run-out cannot be corrected by changing the phase of the brake disc, replace the disc or turn rotor with on the car type brake lathe (“MAD, DL-8700PF” or equivalent).

35A-14

BASIC BRAKE SYSTEM -

On-vehicle Service

BRAKE LINING THICKNESS CHECK

1. Remove the brake drum.

2. Measure the wear of the brake lining at the place worn the most.

Standard value: 4.4 mm Limit: 1.0 mm

Replace the shoe and lining assembly if brake lining thickness is less than the limit or if it is not worn evenly. For information concerning the procedures for installation of the shoe and lining assembly, refer to P.35A-24.

Caution

1. Whenever the shoe and lining assembly is

replaced, replace both R.H. and L.H. assemblies as a set to prevent car from pulling to one side when braking.

2. If there is a significant difference in the thickness

of the shoe and lining assemblies on the left and right sides, check the sliding condition of the piston.

35100300166

BRAKE DRUM INSIDE DIAMETER CHECK

35100320148

1. Remove the brake drum.

2. Measure the inside diameter of t he brake drum at two or more locations.

Standard value: 203 mm Limit: 205 mm

3. Replace brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM CONNECTION CHECK

1. Remove the brake drum.

2. Remove the shoe and lining assembly. (Refer to P.35A-24.)

3. Chalk inner surface of brake drum and rub with shoe and lining assembly.

4. Replace shoe and lining assembly or brake drums if there are any irregular contact area.

NOTE Clean off chalk after check.

35100310169

BASIC BRAKE SYSTEM -

Brake Pedal

35A-15

BRAKE PEDAL

REMOVAL AND INSTALLATION

Post-installation Operation

Brake Pedal Adjustment (Refer to P.35A-6.)

29 Nm

14 Nm

35100340243

12 Nm

13 Nm

Removal steps

1. Stop lamp switch connector

2. Stop lamp switch

3. Snap pin

4. Pin assembly

5. Brake pedal shaft bolt

6. Brake pedal

7. Brake pedal pad

8. Brake pedal return spring

9. Bushing

10. Pipe

11. Pedal support member

35A-16

BASIC BRAKE SYSTEM -

Master Cylinder and Brake Booster

MASTER CYLINDER AND BRAKE BOOSTER

REMOVAL AND INSTALLATION

Pre-removal Operation

Brake Fluid Draining

15 Nm

20 - 25 Nm

Post-installation Operation

D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.) D Brake Pedal Adjustment (Refer to P.35A-6.)

22 Nm

35100370242

14 Nm

10 Nm

15 Nm

<L.H. drive vehicles - 4G6,6A1>

15 Nm

<R.H. drive vehicles - 4D6>

<L.H. drive vehicles - 4D6>

<R.H. drive vehicles - 4G6,6A1>

15 Nm

Sealant: 3M ATD Part No.8661 or equivalent

BASIC BRAKE SYSTEM -

Removal steps

1. Brake pipe connection

2. Brake fluid level sensor connector

3. Master cylinder assembly

"BADPush rod protruding length check and

adjustment

4. Vacuum hose <4D6>

5. Vacuum pipe <4D6>

"AA 6. Vacuum hose

(with built-in check valve)

INSTALLATION SERVICE POINTS

"AA

Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip.

Master Cylinder and Brake Booster

7. Fitting

8. Snap pin

9. Pin assembly

10. Clevis

11. Vacuum switch connector <4D6>

12. Vacuum switch <4D6>

13. Brake booster

14. Sealer

VACUUM HOSE CONNECTION

35A-17

Measuring dimension A

Block gauge

"BA

PUSH ROD PROTRUDING LENGTH CHECK AND ADJUSTMENT

1. Measure dimension A.

Standard value: 9.65 - 9.90 mm

2. If the protruding length is not within the standard value range, adjust by changing the push rod length by turning the end of the push rod.

35A-18

BASIC BRAKE SYSTEM -

Master Cylinder and Brake Booster

MASTER CYLINDER DISASSEMBLY AND REASSEMBLY

35100420145

Master cylinder kit

Disassembly steps

1. Reservoir cap assembly

2. Reservoir cap

3. Diaphragm

4. Brake fluid level indicator assembly

5. Float

6. Spring pin

Brake fluid: DOT3 or DOT4

7. Reservoir tank

8. Reservoir seal

9. Piston retainer

10. Primary piston assembly

11. Secondary piston assembly

12. Master cylinder body

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