MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

BASIC BRAKE SYSTEM -ProportioningValve,MasterCylinder
and Brake BoosterBASIC BRAKE SYSTEM -ProportioningValve,MasterCylinder
and Brake Booster35A-19
2. If the protrusion amount is not within the standard value
range, adjust the push rod length by turning the push
rod. Use the special tool to turn the push rod while holding
the rod spline with angle-nose pliers.
MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
1
2
3838
Brake fluid: DOT3 or DOT4
77
5Master cylinder kit
4
9
6
10
9
8
9
10
Disassembly steps
1. Reservoir cap
2. Filter
3. Spring pin
4. Reservoir tank
5. Reservoir seal6. Pin
7. Piston retainer
8. Primary piston assembly
9. Secondary piston assembly
10. Master cylinder body
Angle-nose pliers
MB991568
Rod spline

BASIC BRAKE SYSTEM -Disc Brake35A-20
DISC BRAKE
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched. And if there is
brake fluid on the caliper, wipe out quickly.
Pre-removal Operation
Brake Fluid DrainingPost-installation Operation
Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
34
21
100±10 N·m
108±10 N·m
30±5 N·m
3 2 1
54±5 N·m
15±2 N·m


4
Removal steps
1. Brake hose connection
2. Gasket
"AA3. Disc brake assembly
4. Brake disc

BASIC BRAKE SYSTEM -Disc Brake35A-21
INSTALLATION SERVICE POINT
"AADISC BRAKE ASSEMBLY INSTALLATION

1. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
(1) Withdraw the drive shaft. (Refer to GROUP 26, 27.)
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
Tightening torque:
245±29 N·m , 225±25 N·m
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
2. Install the caliper support to the knuckle, and then
assemble the pad and the clip to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
7. Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value:
51 N or less , 69 N or less
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the slide pins slide
smoothly.

1. Find the drag force of the disc brake. (Refer to P.35A-13.)
Standard value: 69 N or less
2. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated.MB990998
Bolt


MB990998Bolt
MB990520

BASIC BRAKE SYSTEM -Disc Brake35A-22
DISASSEMBLY AND REASSEMBLY
Front
9
11
1213
4 1
2
4
5
6 89
Brake caliper kit Pad set Seal and boot kit
55 2
3
5
110
8
76
3
9 12
97
Clip set
14
Shim set
11
6
106 31414
14
13
7
74±10 N·m
74±10 N·m 7.9±0.9 N·m
5
57Grease
Disassembly steps
"AA1. Guide pin
"AA2. Lock pin
3. Bushing
4. Caliper support (including pad, clip,
and shim)
5. Pin boot
6. Boot ring
AA"7. Piston bootAA"8. Piston
AB"9. Piston seal
10. Caliper body
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim
14. Clip

BASIC BRAKE SYSTEM -Disc Brake35A-23
Front
Caution
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe out quickly.
9
4 1
2 4
56
8
9
Brake caliper kit
Pad set Seal and boot kit
55
2
3 1 10
87
6
3 9
9 7
Clip setShim set
6
106 3
7 5
7
2 1 2
1
4
Grease: Repair kit grease
14±2 N·m
Disassembly steps
1. Pin
2. Cross spring
3. Pad and wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
AA"7. Piston boot
AA"8. Piston
AB"9. Piston seal
10. Caliper body

BASIC BRAKE SYSTEM -Disc Brake35A-24
Rear
11
1213
4 1
25
6 89
Brake caliper kit Pad set Seal and boot kit
55
2
3
5 1108
76
39 12
97
Clip set
14
Shim set
11
10
6 31414
14
13
44±5 N·m
7.9±0.9 N·m
5
57Grease
4
Disassembly steps
"AA1. Guide pin
"AA2. Lock pin
3. Bushing
4. Caliper support (including pad, clip,
and shim)
5. Pin boot
6. Boot ring
AA"7. Piston bootAA"8. Piston
AB"9. Piston seal
10. Caliper body
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim
14. Clip

BASIC BRAKE SYSTEM -Disc Brake35A-25
Rear
Caution
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe out quickly.
9
4 1 24
5 6
8
9
Brake caliper kit
Pad set Seal and boot kit
5
5 2
3 1 10
876
3 9
9 7
Clip setShim set
6 10 63
7 5
7
21 2 14
Grease: Repair kit grease
14±2 N·m
Disassembly steps
1. Pin
2. Cross spring
3. Pad and wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
AA"7. Piston boot
AA"8. Piston
AB"9. Piston seal
10. Caliper body

BASIC BRAKE SYSTEM -Disc Brake35A-26
LUBRICATION POINTS
Piston seal
Grease: Repair kit grease
Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.
Brake fluid: DOT3 or DOT4
Grease: Repair kit greaseGrease: Repair kit grease

BASIC BRAKE SYSTEM -Disc Brake35A-27
DISASSEMBLY SERVICE POINTS
Caution: Brembo disc brake
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe out quickly.
AA"PISTON BOOT/PISTON REMOVAL

Remove the piston boot by pumping in air slowly from the
brake hose connection. Be sure to use the handle of a plastic
hammer and adjust the height of the two pistons while so
that the pistons protrude evenly.
Caution
Do not remove one piston completely before trying to
remove the other piston, because it will become
impossible to remove the second piston.

Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be
sure to apply compressed air gradually.
AB"PISTON SEAL REMOVAL
1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
Specified brake fluid: DOT3 or DOT4
REASSEMBLY SERVICE POINT
Caution: Brembo disc brake
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe out quickly.

BASIC BRAKE SYSTEM -Disc Brake35A-28
"AALOCK PIN/GUIDE PIN INSTALLATION

As shown in the illustration, align the identification mark on
the caliper body and the head mark of the guide pin/lock
pin, then install the guide pin/lock pin.
INSPECTION
DCheck the cylinder for wear, damage or rust.
DCheck the piston surface for wear, damage or rust.
DCheck the caliper body or sleeve for wear.
DCheck pad for damage or adhesion of grease, check
the backing metal for damage.
PAD WEAR CHECK
Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value:
10.0 mm ,
9.0 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.
Identification
mark ”L”


Front of
vehicle
Rear of
vehicle
Lock pin Lock pin
Guide pin Guide pin
Identification
mark ”G”
Identification
mark ”B”
Identification mark ”A”