brake pads MITSUBISHI 380 2005 Workshop Manual

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-8
STEP 3. Check for interference between the dust cover and
brake disc.
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).
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 PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
.
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.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-9
STEP 3. Adjust the brake pedal or brake booster
pushrod.
Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES :
Go to Step 4.
NO : Adjust the brake pedal or the brake booster
pushrod. 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
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 10.
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 10.
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 10.
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 10.
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 10.
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 10.
NO : Go to Step 7.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-17
BRAKE FLUID LEVEL SENSOR CHECKM1351009100403
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".
DISC BRAKE PAD CHECK AND REPLACEMENTM1351002300398
NOTE: Uneven wearor tapering of brake pad may be caused
by either caliper piston not operating correctly .
Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.
If there is a significant difference in the thicknesses of
the pads on the left and right sides, check the sliding
condition of the piston and slide pins.
1. Check the brake pad thickness through the caliper body
check port.(Rear). Front pad check can be viewed from rotor
side.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-19
3. Remove the following parts from the caliper support.
(1) Pad assembly
(2) Clip
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-30).
5. Install the pads and caliper assembly, and then check the
brake drag force (Refer to P.35A-30).
6. Tighten lock pin bolt. Ensure lock pin is held with spanner
while tightening lock pin bolt(Rear) to specified torque.
DISC BRAKE ROTOR CHECKM1351002900334
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following condi-
tions should be checked.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-20
.
BRAKE DISC THICKNESS CHECK
1. Using a micrometer, measure disc thickness at eight
positions, approximately 45 degrees apart and 10 mm (0.4
inch) in from the outer edge of the disc.
FRONT BRAKE DISC
Standard value: 26.0 mm (1.02 inches)
Minimum limit: 24.4 mm (0.96 inch)
REAR BRAKE DISC
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 8.4 mm (0.33 inch)
NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch). INSPECTION ITEM REMARK
Scratches, rust, saturated lining materials and wear
If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing
will cause warping or distortion.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-31
INSTALLATION SERVICE POINT
.
>>A<< BRAKE DRAG FORCE CHECK
1. In order to measure the brake drag force, measure the hub
torque with the pads removed by the following procedure.
Use a spring scale to measure the hub torque in the forward
direction. Record hub torque with pads removed.
Do not let any oil, grease or other contamination get onto
the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool
MB990520.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and installing the lock
pin bolt.
5. Check the brake drag force as follows.
(1) Start the engine and hold the brake pedal down for 5
seconds. [Pedal depression force: approximately 200 N
(45 pound)]
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-32
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value:
3.8L engine> 64 N (14 pounds) or less
54 N (12 pounds) or less
6. If the brake drag force exceeds the standard value,
disassemble and clean the piston. Check for corrosion or
worn piston seal, and check the sliding condition of the lock
pin and guide pin.
INSPECTIONM1351008100046.
BRAKE DISC CHECK
Disc wear (Refer to P.35A-19).
Disc run-out (Refer to P.35A-19).

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-39
PAD WEAR CHECK
Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
If there is significant difference in the thickness of
the pads on the left and right sides, check the slid-
ing condition of the piston and slide pins.
1. Measure thickness at the thinnest and most worn area of the
pad.
Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
2. Replace the pad assembly if pad thickness is less than the
limit value.

GENERAL00-2
MAINTENANCE SERVICE . . . . . . . .00-37
1. FUEL SYSTEM (TANK, PIPE LINE AND
CONNECTION, AND FUEL TANK FILLER
TUBE CAP) (CHECK FOR LEAKS) . . . . . . 00-37
2. FUEL HOSES (CHECK CONDITION) . . 00-37
3. AIR CLEANER FILTER (REPLACE). . . . 00-37
4. EVAPORATIVE EMISSION SYSTEM
(EXCEPT EVAPORATIVE EMISSION
CANISTER) (CHECK FOR CLOGGING) . . 00-37
5. SPARK PLUGS (REPLACE). . . . . . . . . . 00-38
7. TIMING BELT (REPLACE) . . . . . . . . . . . 00-38
8. DRIVE BELTS (FOR ALTERNATOR, POWER
STEERING PUMP AND AIR CONDITIONING)
(CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-39
9. EXHAUST SYSTEM (CONNECTIONS
PORTION OF MUFFLER, MUFFLER PIPES
AND CONVERTER HEAT SHIELDS) (CHECK
AND SERVICE AS REQUIRED) . . . . . . . . . 00-44
10. ENGINE OIL (CHANGE) . . . . . . . . . . . . 00-4411. ENGINE OIL FILTER (REPLACE) . . . . 00-44
12. TRANSMISSION FLUID . . . . . . . . . . . . 00-45
13. ENGINE COOLANT (CHANGE) . . . . . . 00-47
14. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT). . . . . . . . . . . . 00-49
15. DISC BRAKE PADS, ROTORS
(INSPECT FOR WEAR) . . . . . . . . . . . . . . . 00-49
16. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS) . . . . . . . . . . 00-49
17. BALL JOINT AND STEERING LINKAGE
SEALS (INSPECT FOR GREASE LEAKS
AND DAMAGE) . . . . . . . . . . . . . . . . . . . . . . 00-50
18. DRIVE SHAFT BOOTS (INSPECT FOR
GREASE LEAKS AND DAMAGE) . . . . . . . . 00-50
19. SUSPENSION SYSTEM (INSPECT FOR
LOOSENESS AND DAMAGE) . . . . . . . . . . 00-51
20. SRS AIR BAG (INSPECT FOR SRS
SYSTEM). . . . . . . . . . . . . . . . . . . . . . . . . . . 00-51
21. TYRES (ROTATE). . . . . . . . . . . . . . . . . 00-58

MAINTENANCE SERVICE
GENERAL00-49
14.Remove the radiator cap after the engine has cooled, and
pour in coolant up to the brim. Reinstall the cap.
Do not overfill the radiator condenser tank assembly.
15.Add coolant to the radiator condenser tank assembly
between the "FULL" and "LOW" mark if necessary.
13. COOLANT HOSES (RADIATOR HOSE,
HEATER HOSE) (INSPECT)
M1001009700034
Inspect the surface of radiator hoses and heater hoses for heat
and mechanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indicate deterio-
ration of the rubber.
14. DISC BRAKE PADS, ROTORS (INSPECT FOR
WEAR)
M1001003200291
Check for fluid contamination and wear. Replace the complete
set of pads if any one pad is defective.
Thickness of lining
Minimum limit: 2.0 mm
The pads for the right and left wheels should be replaced
at the same time. Never split or intermix brake pad sets. All
four pads must be replaced as a complete set.
15. BRAKE HOSES (CHECK FOR
DETERIORATION OR LEAKS)
M1001003400314
Inspection of brake hoses should be included in all brake ser-
vice operations.
The hoses should be checked for:
1. Incorrect length, severe surface cracking, stretching,
scuffing or worn spots (If the fabric casing of the hoses is
exposed by cracks or abrasion in the rubber hose cover, the
hoses should be replaced. Eventual deterioration of the
hose and possible bursting failure may occur).
2. Incorrect installation, twisting or interference with wheel, tyre
or chassis.