brake MITSUBISHI 380 2005 Owner's Guide

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-21
After a new brake disc is installed, always grind the
brake disc with an on-the-car type brake lathe. If this
step is not carried out, the brake disc run-out exceeds
the specified value, resulting in judder.
When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.
Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N
m (74
ft-lb). If all of the wheel nuts are not used, or the tight-
ening torque is excessive or not equal, the brake disc
rotor or drum may be deformed, resulting in judder.
2. If the disc thickness is less than the limit, replace it with a
new one. If thickness variation exceeds the specification,
turn rotor with an on-the-car type brake lathe
("Accuturn-8750" or equivalent). If the calculated final
thickness after turning the rotor is less than the standard
value, replace the disc.
.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-22
BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm (0.2 inch) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit:
: 0.10 mm (0.0039 inch)
: 0.04 mm (0.0016 inch)
4. If the brake disc run-out exceeds the limit, correct it as
follows:
(1) Chalk phase marks on the wheel stud and the brake disc
as shown.
(2) Remove the brake disc. Then 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)
(3) If the end play exceeds the limit, replace the hub
assembly.
(4) If the end play does not exceed the limit, dephase the
brake disc and secure it. Then recheck the brake disc
run-out.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-23
After a new brake disc is installed, always grind the
brake disc with an on-the-car type brake lathe. If this
step is not carried out, the brake disc run-out exceeds
the specified value, resulting in judder.
When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.
Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N
m (74
ft-lb). If all of the wheel nuts are not used, or the tight-
ening torque is excessive or not equal, the brake disc
rotor or drum may be deformed, resulting in judder.
5. If the run-out cannot be corrected by changing the phase of
the brake disc, replace the brake disc or grind it with the
on-the-car type brake lathe ("MAD, DL-8700PF" or
equivalent).
MASTER CYLINDER FUNCTION CHECKM1351010200266
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, repair or 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, repair or replace
the master cylinder.

BRAKE PEDAL
BASIC BRAKE SYSTEM35A-24
BRAKE PEDAL
REMOVAL AND INSTALLATIONM1351003400406
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-13).
REMOVAL STEPS
1. BRAKE BOOSTER PIN
2. BRAKE BOOSTER PIN ASSEMBLY
3. SHIFT LOCK CABLE CONNECTION
4. STOPLIGHT SWITCH CONNECTOR
5. STOPLIGHT SWITCH
6. BRAKE PEDAL CLIPWIRING HARNESSES CLAMPED
ON BRAKE PEDAL ASSEMBLY
7. BRAKE PEDAL BOLT
8. BRAKE BOOSTER NUT
9. BRAKE PEDAL ASSEMBLY
10. BRAKE PEDAL PAD
11. BRAKE PEDAL STOPPERREMOVAL STEPS (Continued)

BRAKE PEDAL
BASIC BRAKE SYSTEM35A-25
INSPECTIONM1351003500221.
STOPLIGHT SWITCH CHECK
1. Connect an ohmmeter between the stoplight switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
TESTER
CONNECTIONPLUNGER SPECIFIED
CONDITION
1
2 IN Open circuit
OUT Less than 2

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-26
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
REMOVAL AND INSTALLATIONM1351003700407
Required Special Tool:
MB991568: Push Rod Adjusting Socket
Pre-removal Operation
Strut Tower Bar Removal (Refer to GROUP 42, Strut
To w e r B a r P.42-12).
Battery Removal
Brake Fluid DrainingPost-installation Operation
Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-16).
Brake Pedal Adjustment (Refer to P.35A-13).
Battery Installation
Strut Tower Bar Installation (Refer to GROUP 42, Strut
Tower Bar P.42-12).
BRAKE MASTER CYLINDER
ASSEMBLY REMOVAL STEPS
1. BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR
2. BRAKE TUBE CONNECTION
5. BRAKE MASTER CYLINDER
ASSEMBLY
6. SPRING PIN
7. BRAKE FLUID RESERVOIR
ASSEMBLY
8. MASTER CYLINDER FLUID
RESERVOIR SEAL
9. BRAKE FLUID LEVEL INDICATOR
SWITCH
10. BRAKE FLUID RESERVOIR CAP
BRAKE BOOSTER VACUUM
HOSE REMOVAL STEP
>>A<<11. BRAKE BOOSTER VACUUM
HOSE BRAKE BOOSTER ASSEMBLY
REMOVAL STEPS
1. BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR
2. BRAKE TUBE CONNECTION
5. BRAKE MASTER CYLINDER
ASSEMBLY
>>B< AMOUNT CHECK AND
ADJUSTMENT
>>A<<11. BRAKE BOOSTER VACUUM
HOSE
12. BRAKE BOOSTER PIN
13. BRAKE BOOSTER PIN
ASSEMBLY
14. BRAKE BOOSTER NUT
15. BRAKE BOOSTER ASSEMBLY
16. BRAKE BOOSTER BODY SEAL

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-27
INSTALLATION SERVICE POINTS
.
>>A<< BRAKE BOOSTER VACUUM HOSE
CONNECTION
Insert vacuum hose with its paint mark facing upward.
.
>>B<< PUSH ROD PROTRUSION AMOUNT
CHECK AND ADJUSTMENT
1. Use the vacuum pump to measure dimension "A" applying a
negative pressure of 66.7 kPa (19.7 inHg) to the brake
booster.
Standard value (A): 5.0 mm
0.1

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-28
2. If the protrusion amount is not within the standard value
range, adjust the push rod length by turning the push rod.
Use special tool MB991568 to turn the push rod while
holding the rod spline with angle-nose pliers.
MASTER CYLINDERM1351004200375
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY STEPS
1. BRAKE MASTER CYLINDER TO
FLUID RESERVOIR SEAL
2. BRAKE MASTER CYLINDER PIN
<>3. BRAKE MASTER CYLINDER UNION
RETAINER
4. PRIMARY PISTON ASSEMBLY
5. SECONDARY PISTON ASSEMBLY
6. MASTER CYLINDER BODYDISASSEMBLY STEPS

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-29
DISASSEMBLY SERVICE POINT
.
<> BRAKE MASTER CYLINDER UNION
RETAINER DISASSEMBLY
Remove the brake master cylinder union retainer while
depressing the piston.
INSPECTIONM1351004300297
Check the inner surface of master cylinder body for rust or
pitting.
Check the primary and secondary pistons for rust, scoring,
wear or damage.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-30
DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATIONM1351008000050
Required Special Tool:
MB990520: Disc Brake Piston Expander
Pre-removal Operation
Brake Fluid DrainingPost-installation OperationBrake Fluid Supplying and Air Bleeding (Refer to
P.35A-16).
REMOVAL STEPS
BRAKE FLUID DRAINING
1. BRAKE HOSE CONNECTION
2. GASKET
3. BRAKE CALIPER ASSEMBLY
4. BRAKE DISC
INSTALLATION STEPS
BRAKE FLUID DRAINING
4. BRAKE DISC
3. BRAKE CALIPER ASSEMBLY
2. GASKET1. BRAKE HOSE CONNECTION
BRAKE FLUID SUPPLYING AND AIR
BLEEDING (Refer to P.35A-16.)
>>A<