ect MITSUBISHI LANCER 2005 Workshop Manual

SHOCK ABSORBER ASSEMBLY
REAR SUSPENSION34-18
DISASSEMBLY SERVICE POINTS
<<A>> REAR SUSPENSION COIL SPRING
NUT (SELF-LOCKING NUT) REMOVAL
CAUTION
•To hold the coil spring securely, install
special tool arm set (MB991239) evenly, and
so that the space between both arms of the
special tool will be maximum within the
installation range.
•Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237). It will break the special tool.
1. Use following special tools to compress the coil
spring.
•MB991237: Spring Compressor Body
•MB991239: Arm Set
WARNING
Do not use an impact wrench to remove the
rear suspension coil spring nut (self-locking
nut). Vibration of the impact wrench will
cause special tools (MB991237 and
MB991239) to slip and cause personal injury.
2. While holding the piston rod, remove the rear
suspension coil spring nut (self-locking nut).
<<B>> REAR SUSPENSION SHOCK
ABSORBER DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
The gas must be discharged from the shock
absorber before discarding it. Place the shock
absorber horizontally with its piston rod extended.
Then drill a hole of approximately 3 mm in diameter
at the location shown in the illustration and discharge
the gas.
REASSEMBLY SERVICE POINTS
>>A<< REAR SUSPENSION SPRING
LOWER PAD INSTALLATION
Align the stepped section of the spring lower pad
with the stepped section of the spring seat of the
shock absorber, and install the spring lower pad.
AC001070
MB991237
MB991239
AB
AC102268AC
Piston rod
AC102270
AC
AC304800AB
Spring lower pad
Stepped section
Spring seat

SHOCK ABSORBER ASSEMBLY
REAR SUSPENSION34-19
>>B<< REAR SUSPENSION COIL SPRING
INSTALLATION
CAUTION
Do not use an impact wrench to tighten the bolt
of special tool spring compressor body
(MB991237). It will break the special tool.
1. Use following special tools to compress the coil
spring, and install the rear suspension coil spring
to the spring lower pad.
•MB991237: Spring Compressor Body
•MB991239: Arm Set
2. The rear suspension coil spring lower end must
be positioned as illustrated.
>>C<< REAR SUSPENSION SPRING
UPPER PAD INSTALLATION
Align the stepped section of the spring upper pad
with the upper end of the coil spring, and install the
spring upper pad.
>>D<< REAR SHOCK ABSORBER
INSULATOR INSTALLATION
Install the rear shock absorber insulator so that the
axis of the lower bushing inner pipe of the shock
absorber and the line between the rear shock
absorber insulator mounting bolts are straight when
looking from above.
>>E<< REAR SUSPENSION COIL SPRING
NUT (SELF-LOCKING NUT)
INSTALLATION
1. Temporarily tighten the rear suspension coil
spring nut (self-locking nut).
CAUTION
Do not use an impact wrench to tighten the rear
suspension coil spring nut (self-locking nut),
otherwise the piston rod locking nut inside the
shock absorber will be damaged.
2. Remove the special tools (MB991237,
MB991239), and then tighten the rear suspension
coil spring nut (self-locking nut) to 25 ± 5 N⋅m.
AC001070
MB991237
MB991239
AB
AC304800AC
Less than 10 mm
Stepped section
AC304801AC
Spring upper pad
stepped section
AC304802
Lower bushing inner pipe
Rear shock absorber
insulator mounting bolt
AB
Lower bushing
inner pipe

STABILIZER BAR
REAR SUSPENSION34-21
INSTALLATION SERVICE POINTS
>>A<< STABILIZER
BAR/BUSHING/FIXTURE INSTALLATION
Install the stabilizer bar, the bushings and the fixtures
as illustrated.
>>B<< SELF-LOCKING NUT
INSTALLATION
Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 6 − 8 mm
INSPECTIONM1341001400294
•Check the bushings for wear and deterioration.
•Check the stabilizer bar for deterioration or
damage.
•Check all bolts for condition and straightness.
STABILIZER LINK BALL JOINT TURNING
TORQUE CHECK
1. After shaking the ball joint stud several times,
install the nut to the stud and use special tool
preload socket (MB990326) to measure the
turning torque of the ball joint.
Standard value: 0.5 − 1.5 N⋅m
2. If the measured value exceeds the standard
value, replace the stabilizer link.
3. If the measured value is lower than the standard
value, check that the ball joint turns smoothly
without excessive play. If so, it is possible to
re-use that ball joint.
STABILIZER LINK BALL JOINT DUST
COVER CHECK
1. Check the dust cover for cracks or damage by
pushing it with your finger.
2. If the dust cover is cracked or damaged, replace
the stabilizer link.
NOTE: Cracks or damage of the dust cover may
cause damage to the ball joint. When it is
damaged during service work, replace the dust
cover (Refer to P.34-21).
STABILIZER LINK BALL JOINT DUST
COVER REPLACEMENT
M1341010900242
Only when the dust cover is damaged accidentally
during service work, replace the dust cover as
follows:
AC102279AC
Outside of vehicle
Bushing (LH)
Fixture (LH)Identification colourApproximately
9.5 mm
AC103744
A
AC
AC001129
MB990326
AB

36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . .36-2
SERVICE SPECIFICATIONS . . . . . . .36-2
LUBRICANTS . . . . . . . . . . . . . . . . . .36-3
ON-VEHICLE SERVICE . . . . . . . . . . .36-3
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT . . . . . . . . . . . 36-3
LINING RUNNING-IN . . . . . . . . . . . . . . . . . 36-3
PARKING BRAKE SWITCH CHECK . . . . . 36-4
PARKING BRAKE LEVER . . . . . . . . .36-5
REMOVAL AND INSTALLATION . . . . . . . . 36-5
PARKING BRAKE CABLE . . . . . . . . .36-6
REMOVAL AND INSTALLATION . . . . . . . . 36-6
PARKING BRAKE LINING AND
DRUM . . . . . . . . . . . . . . . . . . . . . . . . .36-7
REMOVAL AND INSTALLATION . . . . . . . . 36-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 36-9

LUBRICANTS
PARKING BRAKES36-3
LUBRICANTS
M1361000400293
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT
M1361000900339
1. Pull the parking brake lever with a force of
approximately 200 N and count the number of
notches.
Standard value: 5 − 7 notches
2. If the parking brake lever stroke is not the
standard value, adjust as described below.
(1) Remove the rear console assembly (Refer to
GROUP 52A, Rear Floor Console P.52A-8).
(2) Loosen the adjusting nut to move it to the
cable rod end so that the cable will be free.
(3) Remove the wheels.
(4) Complete air bleeding of brake circuit. (Refer
to GROUP 35A, On-vehicle Service, Bleeding
P.35A-6.)(5) Remove the rear wheel hub plug, and then
use a flat-tipped screwdriver to turn the shoe
slack adjuster in the direction of the arrow (the
direction which expands the shoe) so that the
disc will not rotate.
Return the shoe slack adjuster 5 notches in
the direction opposite to the direction of the
arrow.
(6) Turn the adjusting nut to adjust the parking
brake lever stroke to the standard value. After
adjusting, check that there is no space
between the adjusting nut and the parking
brake lever. Check that the adjusting nut is
secured with the nut holder.
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
(7) Release the parking brake and turn the rear
wheels to check that the rear brakes are not
dragging.
LINING RUNNING-INM1361001100240
CAUTION
Carry out running-in in a place with good
visibility, and pay careful attention to safety.
Carry out running-in by the following procedure when
replacing the parking brake linings or the rear brake
disc rotors, or when brake performance is
insufficient.
1. Adjust the parking brake lever stroke to the
standard value.
Specified value: 5 − 7 notches (Operation
force: Approximately 200 N) Item Specified lubricant
Rear brake shoe and backing plate contact surface Brake grease SAE J310, NLGI No.1
Rear brake shoe assembly
Rear brake shoe slack adjuster
AC006190
Cable rod
Adjusting nut
AD
AC304403AB
Shoe slack
adjuster

ON-VEHICLE SERVICE
PARKING BRAKES36-4
2. Hook a spring balance onto the centre of the
parking brake lever grip and pull it with a force of
100 − 150 N in a direction perpendicular to the
handle.
3. Drive the vehicle at a constant speed of 35 − 50
km/h for 100 metres.
4. Release the parking brake and let the brakes cool
for 5 − 10 minutes.
5. Repeat the procedure in steps 2 to 4, four or five
times.
PARKING BRAKE SWITCH CHECKM1361003300381
1. Remove the rear console assembly (Refer to
GROUP 52A, Rear Floor Console P.52A-8).
2. Remove the front seat assembly (RH). (Refer to
GROUP 52A, Front Seat P.52A-24).
3. Check for continuity between the parking brake
switch terminal and the switch mounting bolt.
AC212035AC
Spring balance
Approximately
40 mmPull
When parking brake lever is pulled Less than 2 Ω
When parking brake lever is
releasedOpen circuit
AC304746AB

PARKING BRAKE LEVER
PARKING BRAKES36-5
PARKING BRAKE LEVER
REMOVAL AND INSTALLATIONM1361001300330
Pre-removal Operation
Rear Console Assembly and Rear Console Bracket Removal
(Refer to GROUP 52A, Rear Floor Console P.52A-8.)Post-installation Operation
•Parking Brake Lever Stroke Adjustment (Refer to P.36-3.)
•Rear Console Bracket and Rear Console Assembly
Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8.)
AC006199AB
4
5
21
3
A
AB
B
Ratchet pawlSection A - A
Section B - B
Ratchet pawl
Removal steps
1. Adjusting nut
2. Parking brake switch connector
3. Parking brake cable connection
4. Parking brake lever assembly
5. Parking brake switch

PARKING BRAKE CABLE
PARKING BRAKES36-6
PARKING BRAKE CABLE
REMOVAL AND INSTALLATIONM1361001900785
Pre-removal Operation
•Rear Console Assembly and Rear Console Bracket
Removal (Refer to GROUP 52A, Rear Floor Console
P.52A-8).
•Rear Seat Cushion Assembly Removal (Refer to GROUP
52A, Rear Seat P.52A-28).Post-installation Operation
•Parking Brake Lever Stroke Adjustment (Refer to P.36-3).
•Rear Seat Cushion Assembly Installation (Refer to
GROUP 52A, Rear Seat P.52A-28).
•Rear Console Bracket and Rear Console Assembly
Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8).
AC301226
1
AB
2
3
Removal steps
•Rear brake shoe assembly (Refer to
P.36-7).
•Loosen the parking brake lever stroke
adjusting nut.1. Parking brake cable connection
2. Parking brake cable connection
3. Parking brake cableRemoval steps (Continued)

PARKING BRAKE LINING AND DRUM
PARKING BRAKES36-8
REMOVAL SERVICE POINTS
<<A>> REAR BRAKE ASSEMBLY
REMOVAL
Remove the rear brake assembly and support it with
wire or something similar.
<<B>> REAR BRAKE CHAMBER
RETAINER REMOVAL
Use a flat-tipped screwdriver or a similar tool to open
up the rear brake chamber retainer joint. Then
remove the rear brake chamber retainer.
INSTALLATION SERVICE POINTS
>>A<< REAR BRAKE WASHER
INSTALLATION
Install the rear brake washer in the direction shown
in the illustration.
>>B<< REAR BRAKE CHAMBER
RETAINER INSTALLATION
Use pliers or a similar tool to close the rear brake
chamber retainer end onto the pin.
>>C<< SHOE SLACK ADJUSTER
INSTALLATION
Install the shoe slack adjuster so that the shoe
adjusting bolt for the left rear wheel is attached
towards the front of the vehicle, and the shoe
adjusting bolt for the right rear wheel is towards the
rear of the vehicle.
AC000924
AG
Rear brake secondary
shoe assembly pin
Rear brake chamber retainer
AC304675ABRear brake secondary
shoe assemblyRear brake
chamber retainer
Parking brake
operating lever Rear brake
washer
AC000926
AI
Rear brake secondary
shoe assembly pin
Rear brake chamber retainer
AC304676AB
Shoe adjusting bolt
Shoe adjusting bolt
Left rear wheel
Right rear wheel
Rear of
the vehicle
Rear of
the vehicle

PARKING BRAKE LINING AND DRUM
PARKING BRAKES36-9
>>D<< SHOE RETURN SPRINGS
INSTALLATION
The shoe return springs are not interchangeable as
their constants are different. The one with blue paint
mark should be install at the front of the vehicle, and
the other with yellow paint at the rear of the vehicle,
respectively.
NOTE: The illustration shows the left rear wheel. The
right rear wheel is symmetrical to that.
INSPECTIONM1361002600248
PARKING BRAKE LINING AND DRUM
CHECK
1. Measure the thickness of the brake lining at
several places.
Standard value: 2.8 mm
Limit: 1.0 mm
2. If the thickness of the brake lining is below the
limit, replace the shoe assemblies on both sides
of the vehicle. Never replace only one side.
3. Measure the inside diameter of the brake disc in
two places or more.
Standard value: 168.0 mm
Limit: 169.0 mm
4. If the inside diameter exceeds the limit, or if it is
excessively worn on one side, replace the rear
brake disc.
AC202302AC
Front of the vehicle
Blue paint Yellow paint
ACX00708AB
ACX00709