brake MITSUBISHI MONTERO 1991 User Guide
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 179 of 1333
NOTE: Electro-magnetic interference (EMI) may be caused by
incorrect installation of accessories or components. EMI can
result in improper system operation.
BACKING PLATES
BACKING PLATE INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Anchor pin bent ......... B .. Require repair or replacement.
Anchor pin broken ....... A ............ Require replacement.
Anchor pin worn, affecting
structural integrity ... B ............ Require replacement.
Backing plate bent ...... B .. Require repair or replacement.
Backing plate broken .... A ............ Require replacement.
Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting
structural integrity .... A ............ Require replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Shoe lands worn ......... A .. Require repair or replacement.
\
\
\
\
\
\
\
BRAKE FLUID
CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid
in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light
amber in color. DOT 5 brake fluid is violet in color. Correct fluid
required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling
with correct fluid.
Brake fluid type
incorrect .............. B .. Require flushing and refilling
with correct fluid.
Contaminated, for example,
fluid other than brake
fluid present .......... A or B ....... ( 1) Require service.
Hydraulic component ..... 3 .. Suggest flushing and refilling
overhaul or replacement with correct fluid.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .......... ( 2) Require replacement
of gasket.
( 1) - If a fluid other than brake fluid is present in the brake
system which DOES affect the rubber parts, the required
service is to:
* Remove all components having rubber parts from the
system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake
Page 180 of 1333
system which DOES NOT affect the rubber parts, the required
service is to flush and fill with the correct brake fluid.
(Code B)
( 2) - This condition may indicate contaminated brake fluid.
\
\
\
\
\
\
\
BRAKE FRICTION MATERIAL
See FRICTION MATERIAL .
BRAKE PADS
See FRICTION MATERIAL .
BRAKE PEDALS
BRAKE PEDAL INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .... Require replacement of pedal
pad.
Pedal pad worn .......... 1 ............ Suggest replacement.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.
\
\
\
\
\
\
\
BRAKE SHOES
See FRICTION MATERIAL .
BRAKE SHOE HARDWARE
See also SELF-ADJUSTING SYSTEMS .
BRAKE SHOE HARDWARE INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Broken .................. A ............ Require replacement.
Distorted ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Surfaces rust-pitted .... 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
\
\
\
\
\
\
\
BRAKE STOPLIGHT SWITCHES
BRAKE STOPLIGHT INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Page 184 of 1333
![MITSUBISHI MONTERO 1991 User Guide CALIPER INSPECTION \
\
\
\
\
\
\
Condition Code](/img/19/57332/w960_57332-183.png "MITSUBISHI MONTERO 1991 User Guide CALIPER INSPECTION \
\
\
\
\
\
\
Condition Code")
CALIPER INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bleeder port damaged .... A ... Require repair or replacement
of caliper.
Bleeder screw broken off
in caliper ............. A ........... (1) Require repair or
replacement of caliper.
Bleeder screw plugged ... A ........... ( 1) Require repair or
replacement of bleeder screw.
Bleeder screw seized .... A ......... ( 2) Require replacement
of caliper.
Casting corroded,
affecting structural
integrity .............. A ............ Require replacement.
Casting damaged, affecting
structural integrity ... A ............ Require replacement.
Dust boot around caliper
torn ................... A ..... Require replacement of dust
boot.
Leaking ................. A .. Require repair or replacement.
Mounting pin threads
damaged ................ A ... Require repair or replacement
of component with damaged
threads.
Mounting pin threads
stripped in caliper
bracket (threads
missing) ............... A ... Require repair or replacement
of caliper bracket.
Mounting pin threads
stripped in steering
knuckle (threads
missing) ............... A ... Require repair or replacement
of steering knuckle.
Mounting pin threads
stripped (threads
missing) ............... A ... Require repair or replacement
of component with stripped
threads.
Parking brake cable
support, lever, or return
spring bent ............ A ... Require replacement of parts.
Parking brake cable
support, lever, or return
spring broken .......... A ... Require replacement of parts.
Parking brake mechanism in
caliper inoperative .... A .. Require repair or replacement.
Piston corroded (pitted
or peeling chrome
plating) ............... B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, affecting
performance ............ B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, not
affecting performance .. .. ........ No service suggested or
required.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement
Page 188 of 1333
hardware.
Attaching hardware threads
damaged ................ A ... Require repair or replacement
of hardware.
Attaching hardware threads
stripped (threads
missing) ............... A ... Require repair or replacement
of hardware.
Code set (if
applicable) ............ A .......... (1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A .. Require repair or replacement.
Inoperative ............. B .. Require repair or replacement.
( 3) Further inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Refer to manufacturer's diagnostic trouble code procedure
and require repair or replacement of affected component(s).
( 2) - Determine cause and correct prior to repair or replacement
of part.
( 3) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable. Check
for accepted cleaning procedure.
\
\
\
\
\
\
\
FLUID
See BRAKE FLUID.
FLUID LEVEL SENSOR SWITCHES
See SWITCHES.
FOUR WHEEL DRIVE SWITCHES
See SWITCHES.
Page 193 of 1333
![MITSUBISHI MONTERO 1991 User Guide LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION \
\](/img/19/57332/w960_57332-192.png "MITSUBISHI MONTERO 1991 User Guide LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION \
\")
LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Application incorrect ... A ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Broken, affecting
performance ............ A ............ Require replacement.
Broken, not affecting
performance ............ .. ........ No service suggested or
required.
Cracked ................. A ............ Require replacement.
Discolored .............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Melted, affecting
performance ............ A ............ Require replacement.
Melted, not affecting
performance ............ 2 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
\
\
\
\
\
\
\
MASTER CYLINDERS
MASTER CYLINDER INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Brake fluid leaking from
rear of master cylinder
bore ................... B .. Require repair or replacement.
Brake pedal drops
intermittently ......... A ........... ( 1) Require repair or
replacement.
Fluid level low ......... .. ......... ( 2) Further inspection
required.
Internal valve failure .. A .. Require repair or replacement.
Master cylinder leaking
brake fluid internally . A .. Require repair or replacement.
Piston does not return .. A .. Require repair or replacement.
Ports plugged ........... A .. Require repair or replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .. ( 3) Require replacement of the
gasket.
Page 194 of 1333
(1) - This condition may be normal on some vehicles equipped with
anti-lock brakes.
( 2) - Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction
material wear.
( 3) - This condition may indicate contaminated brake fluid.
See BRAKE FLUID .
\
\
\
\
\
\
\
MODULATORS
See HYDRAULIC MODULATORS .
MOTORS
See ELECTRICAL PUMPS AND MOTORS .
PARKING BRAKE SWITCHES
See SWITCHES.
PARKING BRAKE SYSTEMS
NOTE: The parking brake is an integral part of the brake
system. It is important that the parking brake function
properly when brake service is performed.
PARKING BRAKE SYSTEM INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Cable improperly
adjusted ............... B ....... Require cable adjustment.
Cable or individual
wires in the cable
are broken ............. A .... Require replacement of cable
assembly.
Cable sticking .......... A ...... Require cable lubrication.
Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly ..... A .... Require replacement of cable
assembly.
Inoperative ( 1) ......... A .......... Require replacement of
inoperative parts.
Parking brake
parts bent ............. B ... Require repair or replacement
of bent parts.
Parking brake
parts broken ........... A ... Require replacement of broken
parts.
Parking brake parts
Page 195 of 1333
missing ................ C .. Require replacement of missing
parts.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
(1) - Inoperative includes intermittent operation.
\
\
\
\
\
\
\
PADS
See FRICTION MATERIAL .
PEDAL TRAVEL SWITCHES
See SWITCHES.
PEDALS
See BRAKE PEDALS.
POWERMASTER
See HYDRO-BOOSTERS .
PUMPS
See ELECTRICAL PUMPS AND MOTORS .
PRESSURE DIFFERENTIAL SWITCHES
See SWITCHES.
PRESSURE SWITCHES
See SWITCHES.
RELAYS
NOTE: Copied from Electrical UIGs
RELAY INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Housing broken .......... A ............ Require replacement.
Housing cracked ......... 2 ............ Suggest replacement.
Inoperative ( 1) ......... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned,
affecting performance .. A ........... ( 2) Require repair or
replacement.
Page 197 of 1333
reconditioning ......... B ........ (3) Require replacement.
Surface is rust-pitted .. B ....... Require reconditioning or
replacement of rotor according
to OEM specifications.
Surface is scored ....... B ... ( 4) Require reconditioning or
replacement of rotor according
to OEM specifications.
Thickness variation
(parallelism) exceeds OEM
specifications .......... B ....... Require reconditioning or
replacement of rotor according
to OEM specifications.
( 1) - Examples of severe corrosion are: composite plate
separated from friction surfaces and cooling fins
cracked or missing.
( 2) - Only applies to vehicles for which OEM "machine to"
specifications exist. If OEM does not supply "machine
to" specifications, the rotor may be worn to discard
specifications.
( 3) - If OEM does not supply "machine to" specifications,
you may machine to discard specifications.
( 4) - Scoring is defined as grooves or ridges in the friction
contact surface. Some vehicle manufacturers require
machining when scoring exceeds their allowable
specifications.
\
\
\
\
\
\
\
SELF-ADJUSTING SYSTEMS
SELF-ADJUSTING SYSTEM INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent .................... A ... Require repair or replacement
of bent part.
Broken .................. A ... Require repair or replacement
of broken part.
Inoperative ............. A ........... ( 1) Require repair or
replacement of inoperative
parts.
Missing ................. C .......... Require replacement of
missing part.
Star wheel does not turn
freely ................. A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation.
\
\
\
\
\
\
\
SHOE HARDWARE
See BRAKE SHOE HARDWARE .
SHOES
See FRICTION MATERIAL .
SOCKETS
See BULB SOCKETS.
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
Page 199 of 1333
specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
\
\
\
\
\
\
\
STEEL BRAKE LINES
STEEL BRAKE LINE INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
\
\
\
\
\
\
\
STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 208 of 1333
BRAK E S YSTE M
1991 M it s u bis h i M onte ro
1991 BRAKES
Disc & Drum
Chrysler Motors: Ram-50;
Mitsubishi: Montero, Pickup
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake unit, proportioning valve and self-adjusting assembly. Pickup
and Ram-50 models have a Load-Sensing Proportioning Valve (LSPV). All
models are equipped with front disc brakes and rear drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Montero
Bleed brake system in following order: right rear, right
front and left front (one circuit handles both rear brakes).
Pickup & Ram-50
Bleed brake system in following order: right rear, left rear,
LSPV, right front and left front.
ADJUSTMENTS
BRAKE PEDAL HEIGHT & FREE PLAY
1) Separate connector from stoplight switch, and loosen lock
nut. Position switch so it does not contact brake pedal arm. Adjust
brake pedal height by rotating master cylinder push rod (yoke, if
equipped) until distance from top of brake pedal to floor board is
correct. See BRAKE PEDAL SPECIFICATIONS table.
2) DO NOT depress push rod. Tighten lock nut, and ensure
brake pedal height is within specification. Start engine to evacuate
brake booster chamber. Stop engine, and apply brake several times to
remove vacuum from brake booster.
3) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. If distance is incorrect, bleed the
brake hydraulic system, and check for misadjusted brakes. Refer to the
BRAKE PEDAL SPECIFICATIONS table.
BRAKE PEDAL SPECIFICATIONS TABLE
\
\
\
\
\
\
Free Play Pedal Height
Application In. (mm) In. (mm)
Montero ............ .12-.31 (3-8) ... 7.5-7.7 (191-196)
Pickup & Ram-50 .... .12-.31 (3-8) ........... 6.5 (166)
\
\
\
\
\
\
LOAD-SENSING PROPORTIONING VALVE (LSPV) (Pickup & Ram-50)
Park vehicle on level surface. Remove all luggage and
passengers. Ensure lever is not against stopper bolt. Check spring