MITSUBISHI GALANT 1989 Service Repair Manual

35-60SERVICE BRAKES - Service Adjustment Procedures
Pad assembly
\
l4RO367
IWhen newWhen wornI
PadWea 5. Securely attach the pad clip to the caliper support.
6. Apply a coating of the specified grease to the pad, shim
and shim holder installation surfaces, and then install the
shim and shim holder.
Apply the grease so that the grease doesn’t ooze out from
the edges.
Specified grease: Brake grease SAE 5310,
NLGI No. 1
Caution
Do not deposit grease or other dirt on pad or brake disc
friction surfaces.
7.Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the lock pin.
8. Check brake drag torque as follows.
(1) Start engine and hold brake pedal down for 5 seconds.
(2) Stop engine.
(3) Turn brake disc forward IO times.
(4) Check brake drag torque with spring scale.
If the difference between brake drag torque and hub
torque exceeds the standard value, disassemble piston and clean the piston. Check for corrosion or worn piston
seal, and check the sliding condition of the lock pin sleeve
and guide pin sleeve.
Standard value: 70
N (15.4 Ibs.) or less
[4 Nm (3 ftlbs.)]
or less
FRONT DISC BRAKE PAD CHECK AND
REPLACEMENT Y35FaAH
NOTE
The brake pads have been equipped with wear indicators, so
that when the brake pad thickness reached 2 mm
(.08 in.), the
wear indicator touches the brake discs and produces a warning
squeaking sound.
Brake disc

SERVICE BRAKES - Service Adjustment Procedures35-61
ICM-R44V, M-R46V>
MAO563
14AOO23
1.Check brake pad thickness through caliper body check port.
Limit: 2.0 mm
(.08 in.)
Caution
1. When the limit is exceeded, replace the pads on
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 thicknesses
of the pads on the left and right sides, check the
sliding condition of the piston, lock pin and guide
pin.
2. Remove guide pin. Lift caliper assembly and retain with
wire.
Caution
Do not wipe off the special grease that is on the guide
pin or allow it to contaminate the guide pin.
3. Remove the following parts from caliper support.


14Lo293(414N0284
(1) Pad and wear indicator assembly
(2) Pad assembly
(3) Outer shim
(4) Pad clips
(5) Inner shim
TSB Revision

35-62SERVICE BRAKES - Service Adjustment Procedures
u /@$fi 14A0Ol5CM-R56W>
II
I
Pad
c
4s14FOO97
!m
!
bly
c
4. With the pad removed, use a spring balance to measure
the rotation sliding resistance of the hub in the forward di-
rection.
NOTE
Tighten the nuts in order to secure the disc to the hub.
5.Securely attach the pad clip to the caliper support.
6.Clean piston and insert into cylinder with tool.
7. Be careful that the piston boot does not become caught, when lowering the caliper assembly and install the guide
pin.
8.Apply repair kit grease to both sides of the inner shims.
Specified grease: Brake grease SAE 5310,
NLGI No.1
Caution
1. Make sure that the friction surfaces of pads and
brake discs and free of grease and other contami-
nants.
2.The grease should never squeeze out from around
the shim.
9.Check the disc brake drag force as follows.
(1) Start the engine, and after depressing the brake pedal hard two or three times, stop the engine.
(2) Turn brake disc forward
10 times.
(3) Use a spring balance to measure the rotation sliding re- sistance of the hub in the forward direction.
TSB
hevision

SERVICE BRAKES - Service Adjustment Procedures35-63
(4) Calculate the drag torque of the disc brake (difference
between measured values in 3 and 4).
Standard value: 70 N (15.4 Ibs.) or less
10. If the disc brake drag force exceeds the standard value,
disassemble piston and clean the piston. Check for corro-
sion or worn piston seal, and check the sliding condition of
the lock pin and guide pin.
Front Disc Brake Rotor Inspection
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 followi\
ng conditions should be checked.
Inspection items
Scratches, rust, saturated lining materialsand wear
Run-out or drift
Change in thickness (parallelism) Inset or warping (flatness) Remarks
lIf the vehicle is not driven for a certain period, the sections of the d\
iscs
that are not in contact with lining will become rusty, causing noise and\
shuddering.
lIf grooves resulting from excessive disc wear and scratches are not re-
moved prior to installing a new pad assembly, there will momentarily
be inappropriate contact between the disc and the lining (pad).
Excessive run-out or drift of the discs will increase the pedal depressi\
on
resistance due to piston knock-back.
If the thickness of the disc changes, this will cause pedal pulsation, s\
hud-dering and surging.
Overheating and improper handling while servicing will cause inset orwarping.
RUN-OUT CHECKM35F5AB
1.Remove the caliper support; then raise the caliper assem-
bly upward and secure by using wire.
2.Inspect the disc surface for grooves, cracks, and rust. Clean
the disc throughly and remove all rust.
3. Place a dial gauge approximately 5 mm
(.2 in.) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit:

Up to 1991 models
0.08 mm (.0031 in.)
From 1992 models
0.07 mm (.0028 in.)

*1989 models
0.10 mm (.0039 in.)
Up to 1991 models 0.08 mm
(0031 in.)
From 1992 models 0.07 mm
(.0028 in.)
NOTE
Tighten the nuts in order to secure the disc to the hub.
1 TSB Revision

35-64SERVICE BRAKES - Service Adjustment Procedures
RUN-OUT CORRECTIONM35FTAB
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.
14LOOB7
(2) Remove the brake disc, and then place a dial gauge asshown in the illustration; then move the hub in the axial
direction and measure the play.
Limit: 0.2 mm
(.008 in.)
If the play is equivalent to or exceeds the limit, disas-
semble the hub knuckle and check each part.
(3) If the play does not exceed the limit specification, and then check the run-out of the brake disc once again.Mount the brake disc on the position dislocated from
the chalk mark.
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).
THICKNESS CHECK
1.Using a micrometer, measure disc thickness at eight posi-
tions, approximately 45” apart and
10 mm (.39 in.) in from
the outer edge of the disc.
Brake Disc Thickness
Standard value: 24 mm (.94 in.)
Limit: 22.4 mm
(.882 in.)
Thickness Variation (At least 8 position)
The difference between any thickness measure-
ments should not be more than 0.015 mm
(.OOOS
in.).
2.If the disc is beyond the limits for thickness, remove it and
install a new one. If thickness variation exceeds the specifi-
cation, replace the disc or turn rotor with on the car type brake lathe (MAD, DL-8700PF
or equivalent).
TSB Revision

SERVICE BRAKES - Service Adjustment Procedures35-65’
14AO281
WA0204
grooves
Q
0 0
Projection
1410037I-
REAR DISC BRAKE PAD CHECK AND
REPLACEMENT
MBBFUAE
1. Check brake pad thickness through caliper body check port.
Limit: 2.0 mm
(.08 in.)
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 thicknesses
of the pads on the left and right sides, check the
sliding condition of the piston, lock pin sleeve and
.guide pin sleeve.
2.Loosen the parking brake cable (from the vehicle interior),
and disconnect the parking brake end installed to the rear brake assembly.
3. Remove lock pin. Lift caliper assembly and retain with wires.
CautionDo not wipe off the special grease that is
on the lock
pin or allow it to contaminate the lock pin.
Remove the following parts from caliper support.
(1) Outer shim
(2) Pad assembly
(3) Pad clips
C
(4) Pad clips B
4.Measure hub torque with pad removed to measure brake
drag torque after pad installation.
NOT
E
To secure the disc to the hub, tighten the nuts.
5. Securely attach the pad clip to the caliper support.
Caution
Do not deposit grease or other dirt on pad or brake disc
friction surfaces.
6. Clean the piston; then use the special tool to thread the piston into the cylinder.
Be sure, at this time, that the stopper groove of the piston,
correctly fits to the projection on the pad’s rear surface.
7.Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the lock pin.
With the engine running, forcefully depress the brake pedal five or six times, and then check whether or not the
stroke of the parking brake lever is within the standard
value.
If there is a deviation from the standard value, adjust the
stroke of the parking brake lever.
(Refer to GROUP
36-Service Adjustment Procedures.)I) TSB RevisionI

35-66SERVICE BRAKES - Service
Adjustment Procedures
14AOO67
8. Check brake drag torque as follows.
(1) Start engine and hold brake pedal down for 5 seconds.
(2) Stop engine.
(3) Turn brake disc forward 10 times.
(4) Check brake drag torque with spring scale.
If the difference between brake drag torque and hub
torque exceeds the standard value, disassemble piston
and clean piston. Check for corrosion or worn piston seal,
and check the sliding condition of the lock pin sleeve and
guide pin sleeve.
Standard value: 70
N (15.4 Ibs.) or less
14 Nm (3 ft.lbs.)J or less
REAR BRAKE DISC THICKNESS CHECK
M35FVAB
1. Remove dirt and rust from brake disc surface.
2. Measure disc thickness at 4 locations or more.
Limit: 8.4 mm
(.331 in.)
Replace the discs and pad assembly for both sides left
and right of the vehicle if they are worn beyond the
specified limit.
REAR BRAKE DISC RUN-OUT
CHECKM35FWAB
1. Remove the caliper support, raise the caliper assembly, and secure it by using a wire, etc.
2. Place a dial gauge approximately 5 mm
(.2 in.) from the
outer circumference of the brake disc, and measure the run-out of the disc.
Limit: 0.08 mm
(.0031 in.)
NOT
E
To secure the disc to the hub, tighten the nuts.
REAR BRAKE DISC RUN-OUT CORRECTIONMFXAA
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.
NOTE
The procedures for checking by changing the installation
phase of the disc are the same as those for the front brake
discs. (Refer to
P.35-64.)
2.If the problem cannot be corrected by changing the phase
of the brake disc, replace the disc.
TSB Revision

SERVICE BRAKES - Service Adjustment Procedures35-67
BRAKE LINING THICKNESS CHECKM35FlAA
1. Remove the brake drum.
2.Measure the wear of the brake lining at the place worn the
most.
Limit:
1.0 mm (.04 in.)
Replace the shoe and lining assembly if brake lining
thickness is less than the limit and/or if it is not worn
evenly. For information concerning the procedures for installation of the shoe and lining assembly, refer to
P.35-108.
Caution
1.Whenever the shoe and lining assembly is replaced,
replace both RH and LH assemblies as a set to
prevent car from pulling to one side when braking.
2.If there is a significant difference in the. thicknesses
of the shoe and lining assemblies on the left and
right sides, check the sliding condition of the piston.
BRAKE DRUM INSIDE DIAMETER CHECK
Remove the brake drum.
M3!5FJAA
Measure the inside diameter of the hub and drum at two or
more locations.
Limit: 205 mm (8.1 in.) Replace brake drums and shoe and lining assembly when wear
exceeds the limit value or is badly
imbalanced.
TSB Revision
IlAR0170 1
14K664
BRAKE LINING AND BRAKE DRUM CONNECTION
CHECKM35FFAA
1. Remove the brake drum.
2. Remove the shoe and lining assembly. (Refer to
P.35-108.)
3.Chalk inner surface of brake drum and rub with shoe and
lining assembly.
4.Replace shoe and lining assembly or brake drums if very
irregular contact area.
For information concerning the procedures for installation
of the shoe and lining assembly, refer to
P.35-108.
NOTE
Clean off chalk after check.

35-68SERVICE BRAKES - Service Adjustment Procedures
A.B.S. warning light
Ignition switch
sT;!i;%
lARD175
Filter4
kR
14A0171
ANTI-LOCK BRAKING SYSTEM (A.B.S.) CHECK
(CHECKING BY THE A.B.S. WARNING LIGHT)
M35FOAK
By following the procedures described below, check whether
the system is good or not by checking the illumination and non-illumination of the A.B.S. warning light.
(1) Check to be sure that the A.B.S. warning light illuminates
when the ignition key is turned to the ON position, and
that it again illuminates two times during a short period of
time (approximately 0.5 second) after the engine is started, and that it then stops illumination.
(2) After checking that the A.B.S. warning light does not illuminate during a period of approximately 2 minutes
while the engine is left idling, test drive at a vehicle
speed of approximately 30 km/h (18.6 mph) or more for
about 30 seconds or longer and check that the A.B.S.
warning light does not illuminate during that time.
(3) If any abnormal condition is discovered during steps (1) and (2) above, check the system by following the anti-
skid brake system troubleshooting procedures.
Caution
Before checking the anti-lock braking system by the
A.B.S. warning light as described above, first check
the ordinary brake system that there are no problems
such as leakage of the brake fluid, incorrect connec-
tions of the brake tubes, etc.
WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
M3sFoAE
(1) Jack up the vehicle and release the parking brake.
(2) Disconnect the electronic control unit harness connector,
and measure the speed sensor output voltage at the
vehicle side harness connector.
(3) Rotate the wheel to be measured at a speed of about
one-
half to one rotation per second and while doing S
O
measure the speed sensor output voltage by using a
voltmeter or oscilloscope.
(4) If an oscilloscope is used, use the filter shown in the
figure at the left.
Speed sensor1-1 Standard value
1 Front left15-4 (22-4 I50 mV or more 1IIIII
IFront rightI1 23-21 1 23-21 1IIIII1 Rear right1 24-26 1 24-26 1II IIIIII Rear left( 7-9 18-9 1IIII1
NOTE
1. A voltmeter with AC mV range indication should be used
for measurement.
2. When disconnecting the adaptor from the body harness connector, attach a cord to the male connector and then
pull to disconnect.
TSB Revision

SERVICE BRAKES - Service Adjustment Procedures35-69
(5) The probable cause if the output voltage is 50 mV or lower, or if the one-side deflection width of the
oscilloscope’s waveform is 70
mV or lower
Probable causes Remedy
Excessive clearance between the speed sensor pole
piece and rotor Adjust to the standard value.
Foreign material attached to the speed sensor pole
pieceRemove the foreign material.
Damaged speed sensor pole pieceReplace the speed sensor.
Damaged rotor teeth~~~ rReplace the rotor.
Loose speed sensor or rotor installation bolt I
Tighten to the specified torque.
1
NOTE
The speed sensor internal resistance and harness side are normal.
Caution
It is conceivable, because the movement of a speed-sensor cable “foll\
ows” the movement of the front
or rear suspension, that the damaged wiring condition may be apparent on\
ly during travel on poor
road surfaces, and may be normal on better road surfaces. Therefore, whe\
n measuring the output
voltage of a speed sensor, recheck the condition of the cable connection\
s by removing the clamp and pulling the cable and bending it near the clamp position in order to che\
ck for the existence of damaged
wiring.
1/21314j51617)61Q~10~11~12)13~14~15)16~17~1~~19~20~21~22~23~24~25~26(27~26~2Q~30(31~32~33~34~35~
Check connector
74=f=n
ECU
*
Body harnessMB991 356fl 14N018C
MEASUREMENT OF WHEEL SPEED SENSOR
OUTPUT VOLTAGE
IWSFOAQ
1. Lift up the vehicle and release the parking brake.
2. Disconnect the ECU harness connector and measure with the adapter harness (MB991
356) connected to the harness
side connector.
Caution
1. Never insert a probe, etc. into the connector as it
may result in poor contact later.
2.Do not connect the connector (Special Tool) marked
with u*nexcept when recording the waveform on a
driving test. In such a case, connect the connector
to the ECU.
Terminal No. (same for AWD and
FWD)
FL
RR FRRL
4
24218
5
2623 . 9
TSB Revision