MITSUBISHI GALANT 1989 Service Repair Manual

NOTES

35-1
SERVICE BRAKES
CONTENTSM35AA-
ANTI-LOCK BRAKING SYSTEM
TROUBLESHOOTING............................

.
15
BRAKE BOOSTER
................................
.
85
BRAKE FLUID PRESSURE SWITCH
..........
.
133
BRAKE LINE
......................................
.
87
BRAKE PEDAL...................................

.
76
ELECTRONIC CONTROL UNIT

......................134
FRONT DISC BRAKE
............................
.
94
G-SENSOR
....................
.
132
HYDRAULIC UNIT
. . . . . . . . . . . . . . . . . . . . . . 121
MASTER CYLINDER.............................
.
81
REAR BRAKE WHEEL CYLINDER...............

.
111
REAR DISC BRAKE..............................

.
114
REAR DRUM BRAKE.........

.
,.................
.
108
SERVICE ADJUSTMENT PROCEDURES.......

.
53
A.B.S. Power Relay Check
.....................
.
74
Anti-lock Braking System (A.B.S.) Check (Checking by the A.B.S. Warning Light) .........
68
Bleeding .........................................
57
Brake Booster Operating Inspection
...........
.
54
Brake Drum Inside Diameter Check
...........
.
67
Brake Fluid Level Sensor Check ................
54
Brake Fluid Pressure Switch Check
.75
Brake Lining and Brake Drum Connection
Check _. _. . _. _. . .67
Brake Lining Thickness Check ..............
.
Brake Pedal Inspection and Adjustment .....
Check Valve Operation Check ...........
.:...
Delay Valve Check
........
.
Flat Battery Remedy .........................
Front Disc Brake Pad Check and
Replacement ..................................
inspection of Hydraulic Unit ..................
Measurement of Wheel Speed Sensor
Output Voltage ...............................
Proportioning Valve Function. Test ...........
Rear Brake Disc Run-out Check .............
Rear Brake Disc Run-out Correction .........
Rear Brake Disc Thickness Check ...........
Rear Disc Brake Pad Check and
Replacement ..................................
Run-out Check ................................ . 67
. 53
54
74
. 75
59
70
. 69
5
6
. 66
. 66
. 66
. 65
. 63
Run-out Correction . . . . . . . . . . .
64
Thickness Check. . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage Check .
SPECIAL TOOLS.................................
.
11
SPECIFICATIONS................................

.
2
General Specifications
..........................
.
2
Lubricants
......................................
.
11
Sealant and Adhesives
.........................
.
11
Service Specifications
..........................
.
7
Torque Specifications
..........................
.
10
TROUBLESHOOTING............................

.
12
WHEEL SPEED SENSOR.....................

.
126
CAUTION
When servicing brake assemblies or components, do not create dust by san\
ding, grinding or by cleaning
brake parts with a
dry brush or with compressed air. A WATER DAMPENED CLOTH SHOULD BE USED.
Many brake components contain asbestos fibers which can become air-borne\
if dust is created during
service operations. Breathing dust which contains asbestos fibers can ca\
use
seriouj bodily harm.

35-2
SERVICE BRAKES - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS
[up to 1990.5 models1 M3!iCA-

ItemsVehicles without
A.B.S.*
Vehicles with A.B.S.
Master cylinder Type
Tandem type
Tandem type
(with level sensor) (with level sensor)
I.D.mm (in.) 22.2 (718)23.8 (15/16)
Brake boosterType
Vacuum type
Vacuum type
Effective dia. of power cylinder mm (in.) 230 (9.0)Front side: 178 (7.0)
Rear side: 203 (8.0)
Boosting ratio [Brake pedal depressing
force14.0 [at 280 N (62 tbs.)]5.0 [at 270 N (59 Ibs.)l
‘roportioning valve
Split point
kPa (psi) 4,200 (597) 4,200 (597)
Decompression ratio
0.3 0.3
Iront brakesType
Floating caliper, single-
Floating caliper, single-
piston, ventilated disc
(AD54*’ or M-R44V”‘)piston, ventilated disc (AD54*’
or M-R44V**)
Disc O.D. mm (in.) 266 (10.5)
266
(10.5)
Disc thickness mm (in.) 24 (.94)24 i.94)
Pad thicknessmm (in.)
15.5 (.61)*’ or 16 (63)“’15.5 (.61)*’ or 16 (.63)**
Wheel cylinder I.D. mm (in.) 53.9 (2%)
53.9 (2’/8)Clearance
adjustment AutomaticAutomatic
qear disc brakesType
-Floating caliper, single-
piston, non-ventilated
disc
(AD30P)
Disc O.D. mm (in.) -265 (10.4)
Disc thickness
mm (in.) -10 (.39)
Pad thicknessmm (in.) -14.5 (.57)
Wheel cylinder I.D. mm (in.) -30.1 (13/16)
Clearance adjustment-Automatic{ear drum brakes
Type
Leading-trailing
Drum I.D. mm (in.) 203 (8.0)
Wheel cylinder I.D. mm (in.) 17.4
V’/16)
Clearance adjustment
Automatic
Iotor teeth
Front wheel side
98
Rear wheel side-98 ;peed
sensor Magnet coil type
---
NUlt* : Anti-lock Brakina Svstem*I: >
+2: ~1990.5 models

>
TSB RevisionI

SERVICE BRAKES - Specifications35-3

Items
Vehicles without A.B.S.Vehicles with A.B.S.
Master cylinder Type
Tandem type
Tandem type
(with level sensor) (with level sensor)
I.D.mm (in.) 23.8 (15/16)25.4 (I)
Brake boosterType
Vacuum type
Vacuum type
Effective dia. of power cylinder mm (in.) Front side:
178 (7.0)Front side: 203 (8.0)
Rear side: 203 (8.0) Rear side: 230 (9.0)
Boosting ratio [Brake pedal depressing force] 5.0 [at 280
N (62 Ibs.)]5.5 Iat
280 N (62 Ibs.)]
Proportioning valve Split point
kPa (psi) 5,200 (740)5,200 (740)
Decompression ratio 0.40.4
Front brakes Type
Floating caliper, single-
Floating caliper, single-
piston, ventilated disc
(AD54”’ or M-R44V**)
piston, ventilated disc(AD54*’ or M-R44V**)
Disc O.D. mm (in.) 266 (10.5)
266
(10.5)
Disc thickness mm (in.) 24 (.94)24 (.94)
Pad thicknessmm (in.)
15.5 (.61)*’ or 16 (.63)*’15.5 f.61)“’ or 16 (.63)*2
Wheel cylinder I.D. mm (in.) 53.9 (2%) 53.9
(2%)
Clearance adjustment
Automatic
Automatic
Rear disc brakes Type
Floating caliper, single-
Floating caliper, single-
piston, non-ventilated piston, non-ventilated
disc
(AD30P)disc (AD30P)
Disc O.D. mm (in.) 265 (10.4)
265 (10.4)
Disc thickness mm (in.)
10 L39)10 (.39)
Pad thickness
mm (in.) 14.5 f.57)14.5 (.57)
Wheel cylinder I.D. mm (in.) 30.1 (13/16)30.1 (13/16)
Clearance adjustment Automatic
Automatic
Rotor teeth Front wheel side
-86
Rear wheel side 43
Speed sensor Magnet coil type
NOTE+‘: >
**: <1990.5 models

>
TSB Revision

35-4SERVICE BRAKES - Specifications
GENERAL SPECIFICATIONS [Up to 1992 models]

Vehicles without A.B.S.
ItemsVehicles with A.B.S.SOHCDOHC
Master cylinderType
Tandem type
Tandem type
Tandem type
(with level sensor) (with level sensor)(with level sensor)
I.D.mm (in.) 22.2 (7/8)23.8 (15/l 6)
25.4 (I)
Brake booster Type
Vacuum type
Vacuum type
Vacuum type
Effective dia. of power cylinder Front side: 178
(7.0)mm (in.) 230 (9.0)230 (9.0)
Rear side: 203 (8.0)
Boosting ratio 4.05.05.5[Brake pedal depressing force]
[at 280 N (62 Ibs.)][at 220 N (48 Ibs.)][at 250 N (55 Ibs.11
Proportioning valve
Split point
kPa (psi) 4,200 (597)3,700 (526) 3,700 (526)
Decompression ratio0.4 0.30.3
Front brakes Type
Floating caliper, single-
Floating caliper, single-
F!oating caliper, single
piston, ventilated disc y$or&entrlated disc
r;;;6ventrlated drsc(MR44V)
Disc O.D. mm (in.) 256 (10.1)256 (10.1)256 (10.1)
Disc thickness mm (in.) 24
(.94)24 (.94)24 (.94)
Pad thicknessmm (in.) 16 (.63)16 (63)16 (.63)
Wheel cylinder I.D.
mm (in.) 53.9 (2%)60.3 (z3/8)60.3 (23/8)
Clearance adjustment AutomaticAutomatic
Automatic
Rear disc brakes Type
-Floating caliper, single-
piston, non-ventilated Floating caliper, single
piston, non-ventilated
disc
(AD35P)disc (AD35P)
Disc O.D. mm (in.) -265 (10.4)265 (10.4)
Disc thickness mm (in.)
- IO
i.39)
10 (.39)
Pad thickness
mm (in.) -14.5 (57)14.5 (.57)
Wheel cylinder I.D. mm (in.) - 34.9
u3h)34.9 (1%)
Clearance adjustment-Automatic Automatic
Rear drum brakes Type
Leading-trailing
-
Drum I.D.
mm (in.) 203 (8.0)
Wheel cylinder I.D.
mm (in.) 17.4 (‘l/16)--
Clearance adjustment Automatic--3otor
teeth
Front wheel side
98”. 43’2
Rear wheel side--98”. 43’2
speed sensor--Magnet coil type
NOTEl l: 1991 modelsl ? 1992 models
TSB Revision

SERVICE BRAKES - Specifications35-5

Vehicles withoutVehicles with A.B.S.ItemsA.B.S.DOHC (Non-Turbo)
DOHC (Turbo)
Master cylinder Type
Tandem type
Tandem type Tandem type
(with level sensor) (with level sensor) (with level sensor)
I.D.mm (in.) 25.4 (1)25.4 (I)25.4 (I)
Brake boosterType
Vacuum type
Vacuum type Vacuum type
Effective dia. of power Front side: 178
(7.0)Front side: 203 (8.0)Front side: 203 (8.0)cylinde
r
mm

(in.) Rear side: 203 (8.0)
Rear side: 230 (9.0)Rear side: 230 (9.0)
Boosting ratio5.56.06.0[Brake pedal depressing force](at 250 N (55 Ibs.)][at 280 N (62 Ibs.)][at 280 N (62 Ibs.)l
Proportioning valve Split point
kPa (psi) 5,200 (740)5,200 (740) 5,200 (740)
Decompression ratio0.40.40.4
Front brakes Type
Floating caliper, single- Floating caliper, single- Floating caliper,
piston, ventilated disc piston, ventilated disc double-piston,
venti-(M R46V) (MR46V)
lated disc (MR56W)
Disc O.D.
mm (in.) 256
(10.1)256 (10.1)
276 (10.9)
Disc thickness mm (in.) 24
(.94)24 (.94)24 l.94)
Pad thickness mm (in.) 16
(.63)16 (.63)16 (63)
Wheel cylinder I.D. mm (in.) 60.3 (23/s)60.3 (23/8)41.3 (1%) x
2
Clearance adjustment AutomaticAutomatic
Automatic
Rear disc brakes Type
Floating caliper, single-
Floating caliper, single- Floating caliper.
Single-piston, non-ventilatedpiston, non-ventilated piston, non-ventilated
disc (AD35P)disc (AD35P)disc (AD35P)
Disc O.D. mm (in.) 265 (10.4)265 (10.4)
265 (10.4)
Disc thickness mm (in.) 10 (.39)10 l.39)10 l.39)
Pad thickness mm (in.) 14.5
(.57)14.5 (.57)14.5 (57)
Wheel cylinder I.D. mm (in.) 34.9 (13/8) 34.9
(13h) 34.9
(1%8)
Clearance adjustment AutomaticAutomatic Automatic
Rotor teeth Front wheel side
-86”. 43’286”‘. 43’2
Rear wheel side
-4343
Speed sensor-Magnet coil type Magnet coil type
NOTE+I: 1991 model
s
‘2: 1992 models
1 TSB RevisionI

35-6SERVICE BRAKES - Specifications
3ENERAL SPECIFICATIONS [1993 models]
Items
Master cylinder Type
I.D.mm (in.1
Brake booster
Type
Effective dia. of power cylinder mm (in.)
Boosting ratio
[Brake pedal depressing
force1
Proportioning valve Split
point
kPa (psi)
Decompression ratio
Front brakes Type
Disc O.D.
Disc thickness
Pad thickness
Wheel cylinder I.D. Clearance adjustment
Rear disc brakes Type
mm (in.)
mm (in.)
mm (in.)
mm (in.)
Disc O.D.
Disc thickness Pad thickness
Wheel cylinder I.D. Clearance adjustment mm (in.)
mm (in.)
mm (in.)
mm (in.) {ear
drum brakes Type
Drum I.D.
Wheel cylinder I.D. Clearance adjustment
jotor teeth
Front wheel side Rear wheel side mm (in.)
mm (in.)ipeed
sensor
TL
I
Tandem type
(with level sensor)
22.2
(718)
Vacuum type
230
(9.0)
4.0 [at 280 N (62 Ibs.11
4,200 (597)
0.4
Floating caliper, single-
piston, ventilated disc
(M R44V)
256 (10.1)
24
f.94)
16 (.63) 53.9
(2’/8)
Automatic
-
-
-
-
-
I
-eading-trailing
I
SOHC1DOHC1
Vehicles without A.B.S.
Tandem type (with level sensor)
23.8 (15/I
6)
Vacuum type
230
(9.0)
5.0
[at 220 N (48 Ibs.11
3,700 (526)
0.3
Floating caliper, single-
piston, ventilated disc
(MR46V)
256 (10.1)
24 l.94)
16
(.63)
60.3 (23/8)
Automatic
Floating caliper, single-
piston, non-ventilated
disc
(AD35P)
265 (10.4)
10
(.39)
14.5 (.57)
34.9 (1 3/8)
Automatic
TSB Revision
7
Vehicles with A.B.S.
Tandem type (with level sensor)
25.4
(1)
Vacuum type
Front side: 178 (7.0) Rear side: 203 (8.0)
5.5[at 250 N (55 Ibs.11
3,700 (526)
0.3
Floating caliper, single-
piston, ventilated disc
(MR46V)
256 (10.1)
24
(.94)
16 (.63)
60.3 (23/8)
Automatic
Floating caliper, single-
piston, non-ventilated
disc
(AD35P)
265 (10.4)
10 i.39)
14.5
(.57)
34.9 (13/8)
%tomatic
13
I3 dagnet
coil type

SERVICE BRAKES - Specifications357
SERVICE SPECIFICATIONS [Up to 1990.5 models]
ItemsFWDAWD
Standard value Brake pedal height mm (in.) 176-181 (6.9-7.1)176-181
(6.9-7.1)
Brake pedal free play
mm (in.) 3-8 (.I-.3)3-8 (.l-.3)
Brake pedal to floorboard clearancemm (in.) 80 (3.1) or more80 (3.1) or more
Proportioning valve pressure MPa (psi)
Split point 3.95-4.45 (561-633)
i.95-5.45 (704-775)
Output pressure [input pressure]
5.15-5.65 (732-804)*’ 6.55-7.05 (931-1,003)5.55-6.05 (789-861)“’ [9.2 (1.309)][8.2 (1,163)l
Booster push rod to master cylinder piston clearance mm (in.)
9 inch brake booster
0.8-1.0 (.031-,039) -
7 + 8 inch brake booster0.5-0.7 (.020-,028) -
8+9 inch brake booster0.6-0.8 (.024-,031)
Disc brake drag force (tangential force of wheel 70 (15.4) or less
70 (15.4) or less
mounting bolts)N (Ibs.)
Speed sensor’s internal resistance kB
0.8-I .2*30.8-I .2*3
Clearance between the speed pole piece and
0.3-0.9 (.012-.035)*30.3-0.9 (.Ol 2-.035)*3
the toothed rotor mm (in.)
-imit
Left/right proportioning valve output pressure difference
0.4 (57)0.4 (57) MPa
(psi)
Front disc runout
mm (in.) 0.10
(.0039) ‘1,*30.08 (.0031)
0.08(.0031) l 2
Pad thickness mm (in.) 2.0 (08)2.0 (08)
Front disc thicknessmm (in.) 22.4 (.882)22.4 (.882)
Rear disc thicknessmm (in.) 8.4 (.331)8.4 (331)
Rear disc runout
mm (in.) 0.08
(.0031)0.08 (0031)
Rear drum lining thickness mm (in.)
1.0 (04)
Rear drum inside diametermm (in.) 205 (8.1)-
NOTE~1: cl989 models
>
+2: <1990, 1990.5 models>*3: Vehicles with A.B.S.i
TSB Revision

35-8SERVICE BRAKES - SDecifications
SERVICE SPECIFICATIONS [Up to 1992 models]
FWD
Items
AWDSOHCDOHC
Standard value
Brake pedal height mm (in.) 176-181 (6.9-7.1)
176-181
(6.9-7.1)176-181 (6.9-7.1)
Brake pedal free playmm (in.) 3-8 (l-.3)3-8 (.I -.3)3-8 (.I -.3)
Brake pedal to floorboard
clearance mm (in.) 80 (3.1) or more 80 (3.1) or more80
(3.1) or more
Proportioning valve
pressure MPa (psi)
Split point 3.95-4.45
(561-633) 3.45-3.95 (491-561)4.95-5.45 (704-775)
Output pressure5.55-6.05 (789-861) 4.65-5.15 (661-732) 6.55-7.05 (931-[input pressure]
(8.2 (1,163)1[7.7 (1,095)11,003) 19.2 (1,309)1
Booster push rod to
master cylinder piston
clearance mm (in.)
9 inch brake booster
0.8-l .O (.031-,039)0.8-I .O (.031-.039)-
7 +8 inch brake booster0.5-0.7 (.020-.028)0.5-0.7 (.020-.028)
8+ 9 inch brake booster--0.6-0.8 (.024-.031)
Disc brake drag force
(tangential force of wheel
mounting bolts)
N (Ibs.) 70 (15.4) or less 70 (15.4) or less70 (15.4) or less
Speed sensor’s internal
resistance
kQ -0.8-I .2*0.8-1.2”
Clearance between the speed
pole piece and the toothed rotor mm (in.)
-0.3-0.9 (.012-,035)”0.3-0.9 (.012-.035)*
.imit
Left/right proportioning valve
output pressure difference MPa (psi) 0.4 (57)
0.4 (57)0.4 (57)
Front disc runout
mm (in.)
0.08
(.0031), 0.07 (.0028)” 0.08 (0031). 0.07 (0028)”
0.08 (0031). 0.07 (.0028)”
Pad thickness mm (in.) 2.0 (.08)2.0 (.08)2.0 (.08)
Front disc thickness
mm (in.) 22.4 (.882)22.4 (.882)22.4 (.882)
Rear disc thicknessmm (in.) -8.4 (.331)8.4 (.331)
Rear disc runout
mm (in.) -0.08 (.0031)0.08 (.0031)
Rear drum lining thickness
mm (in.) 1.0 (.04)-
Rear drum inside diameter
mm (in.) 205 (8.1)-
NOTEl :Vehicles
with ABSl *: 1992 models
TSB Revision

SERVICE BRAKES - Specifications35-9
SERVICE SPECIFICATIONS [1993 models]
ItemsSOHCDOHC
Standard value
Brake pedal height mm (in.) 176-181 (6.9-7.1)
176-181 (6.9-7.1)
Brake pedal free play mm (in.)3-8 (.I
-.3)3-8 (.I -.3)
Brake pedal to floorboard clearance
mm (in.)80 (3.1) or more 80 (3.1) or more
Proportioning valve pressure MPa
(psi)
Split point 3.95-4.45
(561-633)3.45-3.95 (491-561)
Output pressure5.55-6.05 (789-861)4.65-5.15 (661-732)
[input pressure][8.2 (1 ,I 63)][7.7 (1,095)]
Booster push rod to master cylinder piston clearancemm (in.)
9 inch brake booster0.8-l .O (.031-,039)0.8- 1 .O (.031-.039)
7
+ 8 inch brake booster0.5-0.7 (.020-.028)
Disc brake drag force (tangential force of wheel mounting bolts)
N (Ibs.)70 (15.4) or less 70 (15.4) or less
[Disc brake dragging torque] Nm (ftlbs.)[4 (3) or less] [4 (3) or less]
Speed sensor’s internal resistance
k& -0.8- 1.2*
Clearance between the speed pole piece and the toothed rotor mm (in.) -0.3-0.9 (.012-.035)*
-imit
Left/right proportioning valve output pressure difference
MPa
(psi) 0.4 (57)0.4 (57)
Front disc runout
mm (in.) 0.07 (.0028)0.07 (0028)
Pad thickness mm (in.) 2.0
(.08)2.0 (.08)
Front disc thickness
mm (in.) 22.4 (.882)22.4 (882)
Rear disc thickness
mm(in.) -8.4 (.331)
Rear disc runout
mm (in.) -0.08 (.003 1)
Rear drum lining thicknessmm (in.)1 .O (04)
Rear drum inside diameter
mm (in.) 205 (8.1)
NOTE* : Vehicles with A.B.S.
TSB Revision