MITSUBISHI TRITON 1997 Workshop Manual

35A-2
BASIC BRAKE
SYSTEM
CONTENTS35109000197
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 5. . . . . . . . . . . . . . . . .
LUBRICANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 10. . . . . . . . . . . . . . . . . . . .
Brake Pedal Check and Adjustment 10. . . . . . . . . .
Stop Lamp Switch Check 11. . . . . . . . . . . . . . . . . . . . .
Brake Booster Operating Test 11. . . . . . . . . . . . . . . . .
Check Valve Operation Check 12. . . . . . . . . . . . . . .
Brake Booster Vacuum Switch Check
12. . . . . . . . . . . . . . . . . . .
Bleeding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Fluid Level Sensor Check 13. . . . . . . . . . . . . Load Sensing Spring Length Check and
Adjustment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Sensing Proportioning Valve Function
Test 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Pad Check and Replacement 15. . . . .
Front Disc Brake Rotor Check 16. . . . . . . . . . . . . . .
Brake Lining Thickness Check 17. . . . . . . . . . . . . . .
Brake Drum Inside Diameter Check 18. . . . . . . . . .
Brake Lining and Brake Drum Connection
Check 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PEDAL 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER AND BRAKE
BOOSTER 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VA LV E 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKE 24. . . . . . . . . . . . . . . . . . . . .
REAR DRUM BRAKE 30. . . . . . . . . . . . . . . . . . . . .

BASIC BRAKE SYSTEM ± General Information35A-3
GENERAL INFORMATION35100010120
The brake system has high reliability and durability
which maintains excellent braking performance and
braking feeling. The main features are as follows.

A dual type master cylinder is equipped in all
models.

Both a single type and a tandem type brake
booster have been adopted.
The following type of brake have been adopted.
Front: Floating caliper, 2-piston, ventilated disc
brakes (V4-W43, V5-W43) or floating caliper,
1-piston, ventilated disc brakes (V4-S60,
V5-S60)
Rear: Leading-trailing type drum brake.
Items2WD
vehicles>2WD
vehicles>4WD
vehicles>4WD
vehicles>
Master cylinder I.D. mm23.823.823.823.8
Brake booster effective dia.
of power cylinder mm230
205 + 230*230
180 + 205*205 + 230180 + 205
Brake booster boosting ratio5.05.07.07.0
Load sensing proportioning
valve decompression ratio0.150.150.150.15
Front brake disc effective
dia. mm200200222
228*222
228*
Front brake wheel cylinder
I.D. mm60.3
42.9*60.3
42.9*60.3
42.9*60.3
42.9*
Rear drum brake drum I.D.
mm254254270270
Rear drum brake wheel
cylinder I.D. mm23.823.823.823.8
Rear drum brake lining
thickness mm4.74.74.74.7
NOTE
*: Vehicles with ABS.

B
ra ke b ooste r R
ear b ra ke L
oad s e nsin g
p ro portio nin g v a lv e M
aste r c ylin der R
ear b ra ke
< R .H . d riv e v eh ic le s> B
ra ke b ooste r R
ear b ra ke L
oad s e nsin g
p ro portio nin g v a lv e F
ro nt b ra ke R
ear b ra ke F
ro nt b ra ke

BASIC BRAKE SYSTEM ± Service Specifications35A-5
SERVICE SPECIFICATIONS35100030119
ItemsStandard valueLimit
Brake pedal height mm176 ± 181±
Brake pedal free play mm3 ± 8±
Brake pedal to floor board clearance mm95 or more±
Load sensing proportioning
valve outputpressure kPa
2WDWhen load sensing
spring length is 190
3,625 (5,884)±
valve out ut ressure kPa
(Input pressure kPa)
s ring length is 190
mm (when unladen)5,390 (17,652)±
When load sensing
spring length is 215
mm (when laden)14,393 (17,652)±
4WDWhen load sensing
spring length is 190
4,309 (5,884)±
s ring length is 190
mm (when unladen)6,074 (17,652)±
When load sensing
spring length is 215
mm (when laden)16,310 (17,652)±
Load sensing spring length mm189 ± 193±
Booster push rod to master
cylinder piston clearance mmSingle brake boosterPetrol-powered ve-
hicles0.65 ± 1.05±
Diesel-powered ve-
hicles1.00 ± 1.40±
Tandem brake boosterVehicle which brake
booster of power
cylinder is 180 mm
and 205 mm in
effective diameter0.90 ± 1.30±
Vehicle which brake
booster of power
cylinder is 205 mm
and 230 mm in
effective diameter0.70 ± 1.10±
Front disc brake pad thickness mm102.0
Front brake disc thickness mm2422.4
Front brake disc run-out mm2WD±0.08
4WD±0,06
Front disc brake drag force (tangential force of wheel mounting bolts) N69 or less±
Rear drum brake lining thickness mm4.71.0
Rear drum inside diameter mm2WD254.0256.0
4WD270.0272.0
Front hub end play mm0.05±

L
U BRIC ANTS 35100040105
I te m s S
pecif ie d lu bric a nt B
ra ke flu id D
O T3 o r D O T4 B
ra ke p is to n s e al R
epair k it g re ase G
uid e p in b oot in ner s u rfa ce L
ock p in b oot in ner s u rfa ce P
is to n b oot m ountin g g ro ove s B
ra ke p is to n b oot in ner s u rfa ce L
ock p in b ush in ner s u rfa ce P
is to n c u p s u rfa ce R
ear b ra ke s h oe a nd b ackin g p la te c o nta ct s u rfa ce B
ra ke g re ase S AE J 3 10, N LG I N o.1 A
uto a dju ste r a sse m bly S
pecif ie d s e ala nt R
em ark s V
acu um s w it c h 3
M A T D P art N o.8 661 o r e quiv a le nt S
em i- d ry in g s e ala nt S
hoe h old -d ow n p in 3
M A T D P art N o.8 513 o r e quiv a le nt D
ry in g s e ala nt N
um ber N
am e U
se M
B990964
M B990520
M B990623 B
ra ke to ol s e t P
ush in g-in o f th e d is c b ra ke p is to n
I n sta lla tio n o f d ru m b ra ke w heel c ylin der p is to n
c u p

BASIC BRAKE SYSTEM ± Troubleshooting35A-7
TROUBLESHOOTING35100070081
SymptomProbable causeRemedy
Vehicle pulls to one side
when brakes are applied
Grease or oil on pad or lining surfaceReplace
when brakes are a lied
Inadequate contact of pad or liningCorrect
Auto adjuster malfunctionAdjust
Drum eccentricity or uneven wearRepair or replace as necessary
Insufficient braking powerLow or deteriorated brake fluidRefill or change
Air in brake systemBleed air
Overheated brake rotor due to dragging of pad
or liningCorrect
Inadequate contact of pad or lining
Brake booster malfunction
Clogged brake line
Grease or oil on pad or lining surfaceReplace
Load sensing proportioning valve malfunction
Auto adjuster malfunctionAdjust
Increased pedal stroke
(Reducedpedal to floor
Air in brake systemBleed air
(Reduced edal to floor
board clearance)Worn lining or padReplace
Broken vacuum hose
Faulty master cylinder
Brake fluid leaksCorrect
Auto adjuster malfunctionAdjust
Excessive push rod to master cylinder
clearance
Brake dragIncomplete release of parking brakeCorrect
Clogged master cylinder return port
Incorrect parking brake adjustmentAdjust
Improper push rod to master cylinder
clearance
Faulty master cylinder piston return springReplace
Worn brake pedal return spring
Broken rear drum brake shoe to shoe spring
Lack of lubrication in sliding partsLubricate

BASIC BRAKE SYSTEM ± Troubleshooting35A-8
SymptomProbable causeRemedy
Insufficient parking brake functionWorn brake lining or padReplace
Grease or oil on lining or pad surface
Parking brake cable sticking
Stuck wheel cylinder or caliper piston
Excessive parking brake lever strokeAdjust the parking brake lever stroke or
check the parking brake cable routing
Auto adjuster malfunctionAdjust
Scraping or grinding noise when
brakes are applied
Worn brake lining or padReplace
brakes are a lied
Caliper to wheel interferenceCorrect or replace
Dust cover to disc interference
Bent brake backing plate
Cracked drums or brake disc
Squealing, groaning or chattering
noise when brakes are appliedDisc brakes ± Missing or damaged
brake pad anti-squeak shimReplace
Brake drums and linings, discs and pads
worn or scoredCorrect or replace
Improper lining parts
Disc brake ± Burred or rusted calipersCorrect or deburr
Dirty, greased, contaminated or glazed
liningsClean or replace
Drum brakes ± Weak, damaged or
incorrect shoe hold-down springs, loose
or damaged shoe hold-down pins and
springsCorrect or replace
Incorrect brake pedal or booster push rodAdjust

BASIC BRAKE SYSTEM ± Troubleshooting35A-9
SymptomProbable causeRemedy
Squealing noise
when brakes are
Bent or warped backing plate causing interference with drumReplace
when brakes are
not appliedDrum brakes ± Weak, damaged or incorrect shoe-to-shoe
spring
Poor return of brake booster, master cylinder or wheel
cylinder
Loose or extra parts in brakesRetighten
Improper positioning of pads in caliperCorrect
Improper installation of support mounting to caliper body
Improper machining of drum causing interference with
backing plate or shoeReplace drum
Disc brakes ± Rusted, stuckLubricate or replace
Worn, damaged or insufficiently lubricated wheel bearings
Incorrect brake pedal or booster push rodAdjust
Groaning, clicking or
rattling noise when
Stones or foreign material trapped inside wheel coversRemove stones, etc.
rattling noise when
brakes are not appliedLoose wheel nutsRetighten
Disc brakes ± Loose installation bolts
Worn, damaged or dry wheel bearingsLubricate or replace
Disc brakes ± Failure of shimReplace
Disc brakes ± Wear on sleeve
Incorrect brake pedal or booster push rodAdjust

O
N-V EH IC LE S ER VIC E 35100090131
B RAKE P ED AL C HEC K A ND A DJU STM EN T
B RAKE P ED AL H EIG HT
1 . Turn b ack th e c a rp et e tc . u nder th e b ra ke p edal.
2 . Measu re th e b ra ke p edal h eig ht a s illu str a te d. If it is n ot
w it h in th e s ta ndard v a lu e, a dju st a s fo llo w s.
S ta n dard v alu e: 1 76 ± 1 81 m m ( F ro m t h e s u rfa ce o f
m elt in g s eat t o t h e f a ce o f p ed al p ad )
( 1 ) Dis co nnect th e s to p la m p s w it c h c o nnecto r, lo ose n
t h e lo ck n ut, a nd m ove th e s to p la m p s w it c h to a
p osit io n w here it d oes n ot c o nta ct th e b ra ke p edal
a rm .
( 2 ) Adju st th e b ra ke p edal h eig ht b y tu rn in g th e o pera tin g
r o d w it h p lie rs ( w it h th e o pera tin g r o d lo ck n ut
l o ose ned).
( 3 ) Scre w in th e s to p la m p s w it c h u ntil it c o nta cts th e
b ra ke p edal s to pper ( ju st b efo re b ra ke p edal is c a use d
t o m ove ), r e tu rn th e s to p la m p s w it c h 1 /2 to 1 tu rn
a nd s e cu re w it h th e lo ck n ut.
( 4 ) Connect th e c o nnecto r o f th e s to p la m p s w it c h .
( 5 ) Check to b e s u re th at th e s to p la m p is n ot illu m in ate d
w it h th e b ra ke p edal r e le ase d.
3 . Retu rn th e c a rp et e tc .
B RAKE P ED AL F R EE P LA Y
W it h th e e ngin e s to pped, d epre ss th e b ra ke p edal tw o o r
t h re e tim es. A fte r e lim in atin g th e v a cu um in th e b ra ke b ooste r,
p re ss th e p edal d ow n b y h and, a nd c o nfir m th at th e a m ount
o f m ove m ent b efo re r e sis ta nce is m et ( fr e e p la y) is w it h in
t h e s ta ndard v a lu e r a nge.
S ta n dard v alu e: 3 ± 8 m m
I f th e fr e e p la y e xce eds th e s ta ndard v a lu e, it is p ro bably
d ue to e xce ssiv e p la y b etw een th e c le vis p in a nd b ra ke p edal
a rm .
C heck fo r e xce ssiv e c le ara nce a nd r e pla ce fa ult y p arts a s
r e quir e d. P
edal d ow n
P edal u p
L ock n ut 0
.5 ± 1 .0 m m L
ock n ut O
ute r c a se

W
hen e n gin e is
s to pped W
hen e n gin e is
s ta rte d