brake MITSUBISHI LANCER EVOLUTION IV 1998 Owner's Guide

BASIC BRAKE SYSTEM – Disc Brake35A-10
Rear Brake
Seal & boot kit Shim set
Clip set Pad setBrake caliper kit
1
23 4 5
6
7 8
910
2
6
16
7
8 910 2
1
7
9 7 9
3
4
3 4
2
1
65
5
5
Disassembly steps
1. Pin
2. Cross spring
3. Pad & wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
7. Piston boot
8. Piston
9. Piston seal
10. Caliper body

ABS – Troubleshooting35B-11
3. INSPECTION CHART FOR TROUBLE SYMPTOMS
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptomsInspection pro-
cedure No.Reference page
When the ignition key is turned to “ON” (engine stopped), the ABS warning lamp
does not illuminate.135B-12
Even after the engine is started, the ABS warning lamp remains illuminated.235B-13
After the ignition key is turned to “ON”, the ABS warning lamp blinks twice, and
when turned to “START”, it illuminates. When returned to “ON”, the lamp
flashes once, and then switches off.335B-13
When the ignition key is turned to “START”, the ABS warning lamp does not
illuminate.435B-14
Brake operation is abnormal535B-14
Caution
(1) If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
check if the problem occurred while driving under such conditions as these.
(2) During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.

ABS – Troubleshooting35B-14
INSPECTION PROCEDURE 4
When the ignition key is turned to “START”, the ABS
warning lamp does not illuminate.
Probable cause
The ABS-ECU is powered through IG2 which is turned off when the ignition key
is in START position. The ABS warning lamp is powered through IG1 which is not
turned off even when the ignition key is in START position. So the cause must be
a defective circuit on valve relay side.
Malfunction of wiring harness or connector

Malfunction of valve relay
OK
Check the trouble symptom.NGCheck the harness between the com-
bination meter and valve relay, and
repair if necessary.
OK
Check the motor for operation.NGCheck the harness between the valve
relay and ground, and repair if neces-
sary.
OK
Check the following connector:
A-76NG
Repair
OK
Measure at valve relay connector A-76.

Disconnect the connector and
measure at the harness side.

Disconnect ABS-ECU connector
B-25.

Ignition switch: ON

Voltage between 3 and body
ground
OK:Battery voltageNGCheck the following connectors
and diode:
A-76, B-26NG
Repair
ABS valve relay check.NGReplace the valve relay.
INSPECTION PROCEDURE 5
Brake operation is abnormal
Probable cause
The varies depending on the driving conditions and the road surface conditions, so
problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry
out the following inspection.
Improper installation of wheel speed sensor

Incorrect sensor harness contact

Foreign material adhering to wheel speed sensor

Malfunction of wheel speed sensor

Malfunction of wheel bearing

Malfunction of hydraulic unit

Malfunction of ABS-ECU
NG
Repair
Hydraulic unit checkOKWheel speed sensor inspection. [Refer to Inspection Procedure
for “when either of diagnosis codes No. 11 to 14 is output” (P.35B-3).]

36-1
PARKING
BRAKES
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . .
1. Parking Brake Lever Stroke Check and
Adjustment 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Lining Running-in 4. . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE CABLE 5. . . . . . . . . . . . . . .
PARKING BRAKE DRUM 7. . . . . . . . . . . . . . . .

PARKING BRAKE – Service Specifications / Lubricants / Special Tools36-2
The parking brake is designed as a drum-in-disc brake acting on the rear wheel. This brake is a little
different in construction between EVOLUTION-IV and EVOLUTION-V but much alike in the service procedure
of the parking brake section. In this group, therefore, the description is made only for EVOLUTION-IV.
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Parking brake lever stroke (operating force approx. 196 N {20 kgf})5 – 7 notches–
Brake lining thickness mm2.81.0
Brake drum I.D. mm168169
LUBRICANTS
ItemsSpecified lubricantQuantity
Backing plateCHUO YUKA AKB100As required
Shoe & lining assembly
Adjuster
SPECIAL TOOLS
ToolNumberNameUse
MB990767End yoke holderFixing of hub
MB990241
A: MB990242
B: MB990244Axle shaft puller
A: Puller shaft
B: Puller barRemoval of drive shaft
MB991354Puller body

PARKING BRAKE – On-vehicle Service36-3
ON-VEHICLE SERVICE
1. PARKING BRAKE LEVER STROKE CHECK
AND ADJUSTMENT
1-1 STROKE CHECK
Standard value: 5 – 7 notches
[Operating force of approx. 196 N {20 kgf}]
1-2 STROKE ADJUSTMENT
If the parking brake lever stroke is not the standard value,
adjust as described below.
(1) Loosen the adjusting nut at the floor console to release
the cable.
(2) Remove the adjustment hole plug, and then use a flat-tip
(–) screwdriver to turn the adjuster in the direction of
the arrow (the direction which expands the shoe) until
the disc cannot be rotated by both hands.
Return the adjuster five notches in the direction opposite
to the direction of the arrow. (Reference: shoe clearance
on one side 0.19 mm)
(3) Turn the adjusting nut to adjust the parking brake lever
stroke to the standard value. After adjusting, check that
there is no space between the adjusting nut and the
parking brake lever.
Check also that the adjusting nut is firmly held by the
nut holder.
Caution
If the parking brake lever stroke is below the standard
value and the braking is too firm, the rear brakes
may drag.
(4) After adjusting the parking brake lever stroke, jack up
the rear of the vehicle. Release the parking brake and
turn the rear wheels to check that the rear brakes are
not dragging.
Nut
holder
Adjusting nut
Rear floor console
Adjuster

PARKING BRAKE – On-vehicle Service36-4
2. LINING RUNNING-IN
Carry out running-in by the following procedure when replacing
the parking brake linings or the rear brake disc rotors, or
when brake performance is insufficient.
Caution
Carry out running-in in a place with good visibility, and
pay careful attention to safety.
(1) Adjust the parking brake stroke to the specified value.
Standard value: 5 – 7 notches
[Operating force of approx. 196 N {20 kgf}]
(2) Hook a spring balance onto the center of the parking
brake lever grip and pull it with a force of 98 – 147 N
{10 – 15 kgf} in a direction perpendicular to the handle.
(3) Drive the vehicle at a constant speed of 35 – 50 km/h
for 100 metres.
(4) Release the parking brake and let the brakes cool for
5 – 10 minutes.
(5) Repeat the procedure in steps (2) to (4) 4 – 5 times.
Pull
Spring
balance
Approx.
40 mm

PARKING BRAKE – Parking Brake Cable36-5
PARKING BRAKE CABLE
REMOVAL AND INSTALLATION
Pre-removal Operation

Floor Console and Rear Seat RemovalPost-installation Operation
(1) Parking Brake Lever Stroke Check and Adjustment
(Refer to P.36-3.)
(2) Floor Console and Rear Seat Installation
1
2
3
4
56
78 9
1011 12
13
Unit: Nm {kgf
m}
49 – 59
{5.0 – 6.0}
Backing plate
Brake grease: CHUO YUKA AKB100
10
11
9
8
1111
5
Removal steps
A1. Rear brake caliper assembly
2. Rear brake disc
B3. Shoe-to-anchor spring
4. Adjusting screw spring
A5. Adjuster
6. Strut
7. Strut return springB8. Shoe hold-down cup
9. Shoe hold-down spring
10. Shoe hold-down pin
11. Shoe and lining assembly
12. Clip
13. Parking brake cable

PARKING BRAKE – Parking Brake Cable36-6
REMOVAL SERVICE POINTS
AREAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.
BSHOE HOLD-DOWN CUP REMOVAL
Extend the shoe and lining assembly, and remove the shoe
hold-down cup.
INSTALLATION SERVICE POINTS
AADJUSTER INSTALLATION
Install the adjuster so that the shoe adjusting bolt of left hand
wheel is attached towards the front of the vehicle, and the
shoe adjusting bolt of right hand wheel is towards the rear
of the vehicle.
BSHOE-TO-ANCHOR SPRING INSTALLATION
Install the shoe-to-anchor springs in the order shown in the
illustration.
Caution
The load on the respective shoe-to-anchor springs is
different, so the spring in the figure has been painted.
NOTE
The figure shows the left wheel; for the right wheel, the position
is symmetrical.
Shoe
hold-down
cup
Shoe adjusting
bolt
Rear
(Painted) 1
2

PARKING BRAKE – Parking Brake Drum36-7
PARKING BRAKE DRUM
REMOVAL AND INSTALLATION
Post-installation Operation

Parking Brake Lever Stroke Check and Adjustment
(Refer to P.36-3.)
12
3
4
5 6
7
8
9 10
11 12
1314 15 16
17
Unit: Nm {kgf
m}
118 {12.0}49 – 59
{5.0 – 6.0}
Brake grease: CHUO YUKA AKB100
1111
5
196 – 255
{20.0 – 26.0}
11
9
8
74 – 88
{7.5 – 9.0}
17
Removal steps
1. Rear brake caliper
(Refer to P.36-6.)
2. Rear brake disc
3. Shoe-to-anchor spring
(Refer to P.36-6.)
4. Adjusting screw spring
5. Adjuster
6. Strut
7. Strut return spring
8. Shoe hold-down cup
(Refer to P.36-6.)9. Shoe hold-down spring
10. Shoe hold-down pin
11. Shoe and lining assembly
12. Clip
13. Parking brake cable
14. Split pin
AA15. Drive shaft nut
B16. Rear hub assembly
17. Backing plate