MITSUBISHI SPYDER 1990 Service Repair Manual

BASIC BRAKE. SYSTEM Service Specifications
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Brake pedal height mm (in.) ( 6 . 9 - 7 . 1 )
Brake pedal free mm (in.)3 - 8
Brake pedal to clearance mm (in.)90 (3.5) or moreI
Output pressure of proportioning valve
split point
(psi)
Output pressure of proportioning valve
output fluid pressure (psi) Vehicle without ABS
Vehicle with ABSII
Vehicle without ABS 3.19-3.68 (462-533) I
Vehicle with ABS 3.92-4.41 - - I
valve pressure difference (psi) 0.4 I
Front disc brake pad thickness mm (in.)10
Front disc brake drag force (tangential force of wh
eel mounting bolts) 69 (15.4) or less
(tbs.)
Front brake disc run-out mm (in.)
Front hub end play mm (in.)
2.0
0.05
Front brake disc thickness mm (in.)
Rear brake lining thickness mm (in.)
Rear drum inside diameter mm (in.)2422.4
1
2 3 1 1
Rear disc brake pad thickness mm (in.)10 ,
Rear disc brake drag force (tangential force of whe el mounting bolts)
69 (15.4) or less
(Ibs.)
Rear brake disc thickness mm (in.)
108 . 4
Rear brake disc run-out mm (in.)
Rear hub end play mm (in.)
push rod to master cylinder piston clearance mm (i n.)
9.08
0 . 0 5
T S B R e v i s i o nI

BASIC BRAKE SYSTEM Tools
LUBRICANTS
,,
Brake fluid
Brake piston seal Specified lubricant or
Repair kit grease
Slide pin boot and slide pin bush inner surfaces
,
Brake piston boot inner surfaces.
Lock pin boot inner surfaces
Guide pin boot inner surfaces
Piston boot mounting grooves
Piston cup surface
Rear brake shoe and backing plate contact surfacesB r a k e g r e a s e 1
Shoe and lining assembly and auto adjuster assembly con-
tact surfaces
“.Shoe and lever assembly and auto adjuster assembly con-
tact surfaces
. .. . .
SEALANT
Items
Thread part fitting
Vacuum switch Specified sealant ATD Part No. 8861 or equivalent sealant ,
.
SPECIAL TOOLS
ToolTool number and nameApplication
T S B R e v i s i o n
Brake tool set General service tool
Compressing front disc
piston
Installation of drum brake
wheel cylinder piston cup
Removal and installation of
front hub
Front hub remover and
installer

BASIC BRAKE SYSTEM Troubleshooting
TROUBLESHOOTING
SymptomProbable cause
Remedy
Vehicle pulls to oneGrease or oil on pad or lining surface
Replace
side when brakes are
applied Inadequate contact of pad or lining
C o r r e c t
Auto adjuster malfunctionA d j u s t
Drum out of round or uneven wear Repair or replace a
s necessary
Insufficient braking Low or deteriorated brake fluid Refill or change
power Air in brake system Bleed air from system
Overheated brake rotor due to dragging of pad or
lining
Inadequate contact of pad or lining
Brake booster malfunction
Clogged brake line
pedal
(Reduced
to floorboard
drag
Grease or oil on pad or lining surface
Proportioning valve malfunction
Auto adjuster malfunction
Air in brake system
Worn lining or pad
Broken vacuum hose
Faulty master cylinder
Brake fluid leaks
Auto adjuster malfunction Excessive push rod to master cylinder clearance
Incomplete release of parking brake
Clogged master cylinder return port
Incorrect parking brake adjustment
Incorrect push rod to master cylinder clearance
Faulty master cylinder piston return spring
Worn brake pedal return spring
Broken rear drum brake shoe return spring Replace
Adjust Bleed air from system
Replace
Correct
A d j u s t
Correct
Adjust Replace
Lack of lubrication in sliding parts Lubricate
T S B R e v i s i o n

BASIC BRAKE SYSTEM
Symptom
parking
brake functionProbable cause
Worn brake lining
R e p l a c e
Grease or oil on lining surface
Parking brake cable sticking
Stuck wheel cylinder or caliper piston.
Scraping or grinding
noise when brakes
are applied Excessive parking brake lever stroke
Auto adjuster malfunction
Worn brake lining or pad Caliper to wheel interference
Dust cover to disc interference Adjust the parking brake lever stroke
or check the parking brake cable
routing
.
Adjust
R e p l a c e
Correct or replace
Bent brake backing plate
Cracked drums or brake disc
Squealing, groaning
chattering noise
brakes are
Missing or damaged brake pad anti-squeak shim Replac e
Brake drums and linings, discs and pads worn or Corr ect or replace
scored
Incorrect parts
.
Burred or rusted calipersClean or deburr
Dirty, greased, contaminated or glazed linings Clean or replace
Drum brakes-weak, damaged or incorrect shoe
hold-down springs, loose or damaged shoe
Correct or
hold-down pins and springs,
Incorrect brake pedal or booster push rod setting Adjust
noise whenBent or warped backing plate causing Replace
are not appliedinterference with drum
Drum brakes-weak, damaged or incorrect
shoe-to-shoe spring
Poor return of brake booster, master cylinder or
wheel cylinder
Loose or extra brake parts Retighten
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BASIC BRAKE SYSTEM Troubleshooting .
SymptomProbable cause Remedy
Squealing noise when
positioning of pads in caliper Correct
brakes are not appliedImproper installation of support mounting to
caliper body
Improper machining of drum causing interferenceReplace drum
with backing plate or shoe
Disc brakes-rusted, stuck Lubricate or replace
Worn, damaged or insufficiently lubricated wheel
bearings
Incorrect brake pedal or booster push rod setting Adjust
Groaning clicking orStones or foreign material trapped inside wheel
Remove stones,
rattling noise when covers
brakes are not applied
Loose wheel nuts Retighten
Disc brakes-loose installation bolt
Worn, damaged or dry wheel bearings Lubricate or replace
Disc brakes-failure of anti-rattle shim
R e p l a c e
Disc brakes-wear on sleeve
Incorrect brake pedal or booster push rod settingA d j u s t
,
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BASIC BRAKE SYSTEM .,
d o w n ,
Lock nut
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O N - V E H I C L E
BRAKE PEDAL
BRAKE PEDAL HEIGHT ,
(1) Turn up the carpet, etc. under the brake pedal.(2). Measure the brake
“height as illustrated.
Standard value (A): mm (6.9-7.1 in.)
(3). If the brake pedal height is’not within the st andard;
value, adjust as follows.
(a)Disconnect the stop switch connector, loosen
the lock nut, and move the stop light switch to
a position ‘where it does not contact the brake
pedal arm,.,
(b) Adjust the brake pedal height by
operating rod with pliers (with the operating rod
lock nut loosened), until the correct brake pedal
height is obtained.
(c) Screw in the stop
switch until it contacts
the brake, pedal- stopper (just before the brake
pedal is caused to move). Back off the stop light
switch
to turn and secure by tightening
the lock nut.
(d) Connect the
the stop light switch.
(e) Check to be sure. that, the stop light is not
with the brake
(4) For vehicles with A/T, check the shift locking
mechanism.
(Refer to GROUP 23 On-vehicle Service
Engine (Non-turbo)>.)
(Refer to GROUP 23 On-vehicle Service
Engine (Turbo) and Engine>.)
(5) Turn back the carpet, etc.
2. BRAKE PEDAL FREE PLAY (1) With the engine stopped, press the brake pedal two
or three times. After eliminating the vacuum in the
power brake booster, press the pedal down by hand,
and confirm that the amount of movement before
feeling resistance (the free play) is within the st andard
value range.
Standard value (B): 3-8 mm in.)
(2) If the free play exceeds the standard value, it is
probably due to excessive play between the
pin and brake pedal arm.
Check for excessive clearance and replace faulty pa rts
as required.

BASIC BRAKE SYSTEM
CLEARANCEB E T W E E N B R A K E A N D
REWALL
(1) Turn up thecarpet,etc. under the brake pedal,
(2) Start the engine, depress the brake pedal
with
490 (110 of force.
Standard value 90 mm (3.5 in.)
(3)If the clearance is less than the standard value, c
heck
for air trapped in the brake line,
the lining and the drum, and dragging in the parkin g
brake.
Adjust and replace defective parts as required.
(4) Turn back the carpet,
, .
No continuity Continuity
4
with auto-cruise
control systema
STOP LIGHT SWITCH
Connect a circuit tester to the stop light switch, and check
whether or not there! is continuity when the plunge r of the
stop light switch is pushed in and when it is relea sed.’
The stop light switch is in good condition if there is no
when the plunger is pushed in to a depth of 4 mm
in.) from the outer case edge surface, and if ther e is
continuity when it is released. For vehicles with auto-cruise
controlsystem, the check for
continuity should be made at connectors
and of the
stop light switch.
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BASIC BRAKE SYSTEM On-vehicle Service
GoodNo good
000001
When engine isWhen engine isstopped started
No goodGood
00000184BRAKE BOOSTER OPERATING
For simple checking of the brake booster operation,
carry
out the following tests: 1. Run the engine for one or two minutes; and then turn
the engine off. If the pedal depresses fully the first time but gra dually
becomes higher when depressed succeeding times, the
booster is operating properly. If the
height remains
unchanged, the booster is defective.
2.With the engine stopped, step on the brake pedal se veral
times.
Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster i s in
good condition. If there is no change, the booster is
defective.
3. With the engine running, step on the’ brake peda l and’
then stop the engine. Hold the pedal depressed for 30 seconds. If the ped al,
height does not change, the booster is in condition.
If the pedal rises, the booster is
Brake performance is
all three operating tests.
If the brake booster does not pass all three
there’
may be a fault in the check valve, vacuum
or in
the booster itself.
.

BASIC BRAKE SYSTEM Service
Booster
side
CHECK VALVE OPERATION CHECK
When checking the check valve, keep the check valve fit
in the vacuum hose.,
1. Remove the vacuum hose.
NOTE
The check valve is press-fitted inside the vacuum h ose.
2.Check the operation of the check valve by using a v acuum
Vacuum pump connection Accept/reject criteria
Connection at the brake A negative pressure
booster side (A)is created and held.
Connection at the intake A (vacuum)
manifold side (B) is not created.
Caution
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
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BASIC BRAKE SYSTEM
Pressure gauge
v a l v e
S p l i t p o i n t S p l i t p o i n t
o u t p u t
o u t p u tpressurepressure
Input pressure
VALVE
.
1. two pressure gauges, one ‘each to the
side and output side of the proportioning
2. Air bleed the brake line and
3. While gradually depressing: the brake pedal, the
following measurements and’
be sure that
measured values are within, the allowable
.
Output pressure ‘begins to” drop ‘to input
p r e s s u r e ( s p l i t p o i n t ) .
S t a n d a r d v a l u e :
(2) Check that the output at the standard
value when the input fluid pressure increases;
according to the table
Standard value:
ItemsVehicles without Vehicles with
ABS ABS
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Revision
Input fluid
pressure 6.07 (925) 6.86 (996)
Output fluid
pressure
3.92-4.41
(462-533)
(3) Output pressure difference between left and rig ht
brake lines
Limit: 0.4 (57 psi)
4.If the measured pressures are not within allowable ranges,
replace the proportioning valve.