Basic Brake System - Lancer Evolution Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

Top components such as Brembo™ brakes, EBD and sports ABS improve braking power and braking stability.

IMPROVED BRAKING PERFORMANCE

1. A 8+9-inch tandem vacuum booster is utilized to provide high braking force with a small pedal depression force.
2. Brembo™ 17-inch 4-pot front ventilated disc brakes and Brembo™ 16-inch 2-pot rear ventilated disc brakes provide stable braking force and improved braking feel.

IMPROVED STABILITY

1. Sports ABS (4-wheel anti-lock braking system) is used to prevent slipping caused by the vehicle wheels locking up in order to maintain an appropriate braking distance, and also to maintain a stable vehicle posture and steering performance.
2. Adoption of an electronic brake-force distribution (EBD) makes it possible to maintain the maximum amount of braking force even when the vehicle's load is unevenly distributed. < Vehicles with ABS >
3. Front- and rear-wheel X-type brake line layout is used.
4. Ventilated discs improve anti-fading performance.

IMPROVED SERVICEABILITY

1. A diagnosis function for the ABS system makes inspection easier.
2. An outer disc method separated hub and rotor makes removal and installation easier.
3. The master cylinder reservoir tank cap is colored white to make identification easier.
4. The ABS-ECU and hydraulic unit are integrated to make them more compact and lightweight.

CONSTRUCTION DIAGRAM

< VEHICLE WITH ABS >

Scheme 84

< VEHICLE WITHOUT ABS >

Scheme 85

INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS

Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster and disc brakes. Malfunctions such as insufficient braking power or the generation of noise may occur due to wear, damage or incorrect adjustment of these components.

BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a basic brake system fault.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the symptom chart.
4. Verify malfunction is eliminated.

SYMPTOM CHART

SYMPTOM CHART

DIAGNOSIS

1. STEP 1. Check for oil, water, etc., on the pad contact surface of all brakes. Q: Is oil, water, etc., on the pad contact surface? YES: Replace the part. Determine and repair the source/cause of foreign material. Then go to Step 5 . NO: Go to Step 2.
2. STEP 2. Check disc brake pistons for smooth operation. With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserves. Test each disc brake assembly one at a time. Remove the lower caliper bolt, then remove caliper from mount. Have an assistant slowly depress the brake pedal. Confirm piston(s) extend slowly and smoothly with no jumpiness. Repeat for each disc brake assembly. Q: Do (does) the piston(s) move correctly? YES: Go to Step 3. NO: Disassemble and inspect the brake assembly (Front: refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) , Rear: refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) ). Then go to Step 5 .
3. STEP 3. Check brake disc(s) for run out. Refer to «BRAKE DISC RUN-OUT CHECK AND CORRECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__brake-disc-run-out-check-and-correction) . Q: Is runout outside of specifications? YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5 . NO: Go to Step 4.
4. STEP 4. Check brake discs for correct thickness. Refer to «DISC BRAKE ROTOR CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__disc-brake-rotor-check) . Q: Is the thickness outside of specifications? YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5. NO: Carry out the brake line bleeding. Then go to Step 5.
5. STEP 5. Retest the system. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at Step 1 . If a new symptom appears, refer to the appropriate «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

1. STEP 1. Check that the specified brake fluid is used, its level is correct, and no contamination is found. Q: Is there fault? YES: Refill or replace with the specified brake fluid DOT 3 or DOT 4. Bleed the brakes if necessary (Refer to «BLEEDING»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__bleeding) ). Then go to Step 7 . NO: Go to Step 2.
2. STEP 2. Check for spongy (not firm brakes). With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserve. With the brake pedal fully released, depress the brake pedal slowly until it stops. With a measuring stick (ruler, etc.) next to the brake pedal, depress the pedal firmly and measure the distance the pedal traveled. Q: Is the distance greater than 20 mm (0.8 inch)? YES: Bleed the brakes to remove air in the fluid (Refer to «BLEEDING»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__bleeding) ). Then go to Step 7 . NO: Go to Step 3.
3. STEP 3. Check the brake booster function. Refer to «BRAKE BOOSTER OPERATING TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) . Q: Is there fault? YES: Replace the brake booster. Then go to Step 7 . NO: Go to Step 4.
4. STEP 4. Check for pinched or restricted brake tube or hose. Q: Is there a pinched or restricted brake tube or hose? YES: Replace that complete section of brake tube or brake hose. Then go to Step 7 . NO: Go to Step 5.
5. STEP 5. Check for oil, water, etc., on the pad contact surfaces of all brakes. Q: Is oil, water, etc., on the pad contact surface? YES: Replace the part. Determine and repair the source/cause of foreign material. Recheck symptom. Then go to Step 7 . NO < Vehicle without ABS >: Go to Step 6. NO < Vehicle with ABS >: The procedure is complete.
6. STEP 6. Check the proportioning valve operation. Refer to «CHECK VALVE OPERATION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__check-valve-operation-check) . Q: Is there fault? YES: Replace the part. Then go to Step 7. NO: Go to Step 7.
7. STEP 7. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the appropriate «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

1. STEP 1. Check for spongy (not firm brakes). With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserve. With the brake pedal fully released, depress the brake pedal slowly until it stops. With a measuring stick (ruler, etc.) next to the brake pedal, depress the pedal firmly and measure the distance the pedal traveled. Q: Is the distance greater than 20 mm (0.8 inch)? YES: Bleed the brakes to remove air in the fluid (Refer to «BLEEDING»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__bleeding) ). Then go to Step 7 . NO: Go to Step 2.
2. STEP 2. Check the pad for wear. Refer to «FRONT DISC BRAKE PAD CHECK AND REPLACEMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__front-disc-brake-pad-check-and) . Q: Is the pad thickness outside of specifications? YES: Replace the part. Then go to Step 7 . NO: Go to Step 3.
3. STEP 3. Check the vacuum hose and check valve for damage. Refer to «CHECK VALVE OPERATION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__check-valve-operation-check) . Q: Is there damage? YES: Replace the part. Then go to Step 7 . NO: Go to Step 4.
4. STEP 4. Check the master cylinder function. Refer to «MASTER CYLINDER FUNCTION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__master-cylinder-function-check) . Q: Is there fault? YES: Repair it. Then go to Step 7 . NO: Go to Step 5.
5. STEP 5. Check for brake fluid leaks. Q: Is there leaks? YES: Check the connection for looseness, corrosion, etc. Clean and repair as necessary. If leaking in any tube or hose section, replace the complete tube or hose. Then go to Step 7 . NO: Go to Step 6.
6. STEP 6. Check the clearance (too much) between the push rod and primary piston. Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) . Q: Is the clearance outside of specifications? YES: Adjust the clearance. Then go to Step 7. NO: Go to Step 7.
7. STEP 7. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

Scheme 86

Scheme 87

1. STEP 1. Check the parking brake operating lever return. Q: Is there fault? YES: Repair or replace it. Then go to Step 9 . NO: Go to Step 2.
2. STEP 2. Check the brake shoe springs for breakage. Q: Are the brake shoe springs broken? YES: Replace the spring. Then go to Step 9 . NO: Go to Step 3.
3. STEP 3. Check the amount of grease at each sliding section. Refer to «PARKING BRAKE LINING AND DRUM»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/parking-brake-system/#parking-brakes-lancer-evolution) . Q: Is there insufficient grease? YES: Apply grease. Then go to Step 9 . NO: Go to Step 4.
4. STEP 4. Check the parking brake lever effort. Refer to «PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/parking-brake-system/#parking-brakes-lancer-evolution) . Q: Is there fault? YES: Adjust it. Then go to Step 9 . NO: Go to Step 5.
5. STEP 5. Check the clearance (too low) between the push rod and primary piston. Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) . Q: Is there fault? YES: Adjust the clearance. Then go to Step 9 . NO: Go to Step 6.
6. STEP 6. Check the master cylinder piston return spring for damage and return port for clogging. Refer to «MASTER CYLINDER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) . Q: Is there damage? YES: Replace the part. Then go to Step 9 . NO: Go to Step 7.
7. STEP 7. Check port for clogging. Q: Is the port clogged? YES: Repair it. Then go to Step 9 . NO: Go to Step 8.
8. STEP 8. Check disc brake pistons for sticking. Depress the brake pedal, then release. Confirm each wheel spins freely. Q: Are all wheels stuck? YES: Inspect that brake assembly. Then go to Step 9. NO: Go to Step 9.
9. STEP 9. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

Scheme 88

1. STEP 1. Check the front brakes, then rear brakes, for metal-to-metal condition. Q: Is the metal-to-metal contact evident? YES: Repair or replace the components. Then go to Step 6 . NO: Go to Step 2.
2. STEP 2. Check for interference between the caliper and wheel. Q: Is there interference? YES: Repair or replace the part. Then go to Step 6 . NO: Go to Step 3.
3. STEP 3. Check for interference between the dust cover and brake disc. Q: Is there interference? YES: Repair or replace the part. Then go to Step 6 . NO: Go to Step 4.
4. STEP 4. Check the brake discs for cracks. Q: Are there cracks? YES: Repair or replace the part. Then go to Step 6 . NO: Go to Step 5.
5. STEP 5. Check for bent backing plate(s). Q: Is (Are) the backing plate(s) bent? YES: Repair or replace the part. Then go to Step 6. NO: Go to Step 6.
6. STEP 6. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

1. STEP 1. Check the brake disc and pads for wear or cutting. Q: Is there wear or cutting? YES: Repair or replace the part. Then go to Step 4 . NO: Go to Step 2.
2. STEP 2. Check the calipers for rust. Q: Is there rust? YES: Remove the rust. Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Adjust the brake pedal or brake booster pushrod. Refer to «BRAKE PEDAL CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) or «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) . Q: Are the brake pedal and the brake booster pushrod adjusted correctly? YES: Go to Step 4. NO: Adjust the brake pedal or the brake booster pushrod. Then go to Step 4.
4. STEP 4. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at Step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

Scheme 89

Scheme 90

1. STEP 1. Check whether the backing plate is bent or loose and interfering with the drum. Q: Is there fault? YES: Replace the part. Then go to Step 10 . NO: Go to Step 2.
2. STEP 2. Check whether the drum is damaged due to interference with the backing plate or shoe. Q: Is there damage? YES: Replace the part. Then go to Step 10 . NO: Go to Step 3.
3. STEP 3. Check the brake drum for wear and the shoe spring for damage. Q: Is there wear or damage? YES: Replace the part. Then go to Step 10 . NO: Go to Step 4.
4. STEP 4. Check the brake discs for rust. Q: Are the brake discs rusted? YES: Remove the rust by using sand paper. If still rusted, turn the rotors with an on-the-car brake lathe. Then go to Step 10 . NO: Go to Step 5.
5. STEP 5. Check the brake pads for correct installation. Q: Are the pads installed incorrectly? YES: Repair the pads. Then go to Step 10 . NO: Go to Step 6.
6. STEP 6. Check the calipers for correct installation. Q: Are the calipers installed incorrectly? YES: Repair the calipers. Then go to Step 10 . NO: Go to Step 7.
7. STEP 7. Check the wheel bearings for end play. Remove the brake discs. Place a dial gauge as shown, and measure the end play while moving the hub in the axial direction. Limit: 0.05 mm (0.002 inch) Q: Does the measured end play exceed the limit? YES: Replace the faulty hub assembly. Then go to Step 10 . NO: Go to Step 8.
8. STEP 8. Check whether the brake booster or master cylinder return is insufficient. Q: Is the brake booster or master cylinder return insufficient? YES: Replace the part. Then go to Step 10 . NO: Go to Step 9.
9. STEP 9. Adjust the brake pedal or brake booster pushrod. Refer to «BRAKE PEDAL CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) or «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) . Q: Are the brake pedal and the brake booster pushrod adjusted correctly? YES: Go to Step 10. NO: Adjust the brake pedal or the brake booster pushrod. Then go to Step 10.
10. STEP 10. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at Step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

1. STEP 1. Check whether foreign material has entered the wheel covers. Q: Is there foreign material? YES: Remove it. Then go to Step 5 . NO: Go to Step 2.
2. STEP 2. Check for looseness of the wheel nuts. Q: Are the wheel nuts loose? YES: Tighten to 98 +/- 10 N. m (73 +/- 7 ft-lb). Then go to Step 5 . NO: Go to Step 3.
3. STEP 3. Check for looseness of the caliper installation bolt. Q: Is the caliper installation bolt loose? YES: Tighten to 108 +/- 10 N. m (80 +/- 7 ft-lb) for the front caliper. Tighten to 54 +/- 5 N. m (40 +/- 4 ft-lb) for the rear caliper. Then go to Step 5 . NO: Go to Step 4.
4. STEP 4. Check the wheel bearings for end play. Remove the brake discs. Place a dial gauge as shown, and measure the end play while moving the hub in the axial direction. Limit: 0.05 mm (0.002 inch) Q: Does the measured end play exceed the limit? YES: Replace the faulty hub assembly. Then go to Step 5. NO: Go to Step 5.
5. STEP 5. Recheck symptom. Q: Is the symptom eliminated? YES: The procedure is complete. NO: Start over at step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__symptom-chart) .

SPECIAL TOOLS

SPECIAL TOOLS SPECIFICATIONS TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MB991568 Push rod adjusting socket General service tool Adjustment of the brake booster push rod protrusion amount MB990964 Brake tool set MB990520 Disc brake piston expander MB990619 Installer MB990619-01 or general service tool Pushing-in of the disc brake piston Installation of the drum brake wheel cylinder piston cup

Scheme 91

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1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated. Standard value (A): 169.1 -172.1 mm (6.7 -6.8 inches) [From the surface of melting sheet (floorboard) to the face of pedal pad]
3. If the brake pedal height is not within the standard value, follow the procedure below. Disconnect the stoplight switch connector. Loosen the stoplight switch by turning it approximately. 1/4 turns anticlockwise. Remove the brake booster. (Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) .) NOTE: With the master cylinder and brake pipe connected, remove the brake booster only. Adjust the brake pedal height by turning the clevis. NOTE: When the clevis is turned 180 degrees, the pedal height is changed approximately 2.4 mm (0.09 in). Install the brake booster. (Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) .) Measure the brake pedal height, and ensure that the measured value is within the specified value. When it is out of the specified value, repeat Step (3) - (6). Insert the stoplight switch until its threaded part touches the stopper. Then lock the stoplight switch by turning it approximately 1/4 turn clockwise, and confirm that the clearance between the switch plunger and the stopper is as shown. CAUTION: Check that the stoplight does not illuminate when the brake pedal is not depressed. Connect the connector at the stoplight switch.
4. Return the carpet, etc.

Scheme 96

1. With the engine stopped, depress 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 resistance is met (the free play) is within the standard value. Standard value (B): 3 - 8 mm (0.12 - 0.31 inch)
2. If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary: Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod Brake pedal height Installation position of the stoplight switch, etc.

Scheme 97

1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with approximately 500 N (112 pounds) of force, and measure the clearance between the brake pedal and the floorboard. Standard value (C): 90 mm (3.5 inches) or more [From the surface of the floorboard to the face of pedal pad]
3. If the clearance is outside the standard value, check for air trapped in the brake line and thickness of the disc brake pad. And then bleed the air and replace the disc brake pad as required.
4. Return the carpet etc. to its original position.

Scheme 98

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Scheme 100

1. For simple checking of the brake booster operation, carry out the following tests: Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly. If the pedal height remains unchanged, the booster is defective. Go to step 2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective. Go to step 3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective.
2. If the above three tests are okay, the booster is OK. If one of the above three tests is not okay, the check valve, vacuum hose, or booster is defective. Check the check valve operation (Refer to «CHECK VALVE OPERATION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__check-valve-operation-check) ), vacuum hose for leaks, high volume engine vacuum applied to booster. Repair or replace as necessary. If these are OK, replace the booster and repeat this test starting at Step 1.

CHECK VALVE OPERATION CHECK

Scheme 101

1. Remove the vacuum hose. (Refer to «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution) .) CAUTION: If the check valve is defective, replace it as an assembly together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum pump. VACUUM PUMP CONNECTION SPECIFICATIONS VACUUM PUMP CONNECTION CRITERIA Connection at the brake booster side (A) A negative pressure (vacuum) is created and held. Connection at the intake manifold side (B) A negative pressure (vacuum) is not created.

PROPORTIONING VALVE FUNCTION TEST < VEHICLES WITHOUT ABS >

Scheme 102

Scheme 103

1. Connect two pressure gauges to the output port of the master cylinder and output port of the proportioning valve.
2. Bleed the brake line and the pressure gauges (Refer to «BLEEDING»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__bleeding) ).
3. Depress the brake pedal gradually. Then check that the split point, where the output fluid pressure begins to drop in proportion to the output fluid pressure, is at the standard value. Standard value: 2.70 - 3.19 MPa (392 - 463 psi)
4. Depress the brake pedal more strongly than at the above step. Then check that the output fluid pressure is at the standard value when the input fluid pressure is 6.86 MPa (995 psi). Standard value: 3.68 - 4.17 MPa (534 - 605 psi)
5. Measure each output fluid pressure at both valves, and check that the difference between the two is at the limit value or less. Limit: 0.5 MPa (73 psi)
6. If the measured pressure exceeds the limit, replace the proportioning valve.

BLEEDING

MASTER CYLINDER BLEEDING

The master cylinder has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.)

Scheme 104

1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 - 4 three or four times to fill the inside of the master cylinder with brake fluid.

DISC BRAKE BLEEDING

Scheme 105

BRAKE LINE BLEEDING

Scheme 106

BRAKE FLUID LEVEL SENSOR CHECK

The brake fluid level sensor is in good condition if there is no continuity when the float surface is above "MIN" and if there is continuity when the float surface is below "MIN".

Scheme 107

FRONT DISC BRAKE PAD CHECK AND REPLACEMENT

Required Special Tools

1. MB990520: Piston Expander

Note. The brake pads have indicators that contact the brake disc when the brake pad thickness becomes 2 mm (0.08 inch), and emit a squealing sound to warn the driver.

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1. Check the brake pad thickness through the caliper body check port. Standard value: < Front > 10.0 mm (0.39 inch) < Rear > 9.0 mm (0.35 inch) Minimum limit: 2.0 mm (0.08 inch)
2. When the thickness is less than the limit, always replace the pads at an axle set. Holding the cross spring with one hand, pull the pin out of the caliper. Remove the pad from the caliper. To measure brake drag force after new pads have been installed, use a spring scale to measure the turning sliding resistance of the hub with the pads removed. Clean the piston and, using special tool MB990520, push the piston into the cylinder. Apply repair kit grease to the portions of the pads indicated on the left. At this time, make sure that the grease will not be applied to any other surfaces. Mount the pads to the caliper so that its side with the wear indicator is on the outside of the vehicle. With the rear pads, ensure that the arrow on the pad faces in the same direction as the brake disc turns when the vehicle moves forward. Holding the cross spring with one hand, fit pins in the caliper. Using a spring scale, measure the turning sliding resistance of the hub in the forward direction. Find the brake disc drag force [the difference in measurements taken in step(3) and in step(8)]. Standard value: 69 N (15 pounds) or less If that drag force exceeds the standard value, disassemble the caliper assembly. Then check the piston for contamination or rust, and confirm if the piston or the piston seal is deteriorated.

DISC BRAKE ROTOR CHECK

Before turning the brake disc, the following conditions should be checked.

BRAKE DISC SPECIFICATIONS

BRAKE DISK THICKNESS CHECK

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1. Using a micrometer, measure disc thickness at eight positions, approximately 45 degrees apart and 10 mm (0.39 inch) from the outer edge of the disc. Standard value: < Front > 32.0 mm (1.26 inch) < Rear > 22.0 mm (0.87 inch) Minimum limit: < Front > 29.8 mm (1.17 inch) < Rear > 20.4 mm (0.80 inch) NOTE: Thickness variation (at least 8 positions) should not be more than 0.015 mm (0.0006 inch). CAUTION: After a new brake disc is installed, always grind the brake disc with on-the-car type brake lathe. If this step is not carried out, the brake disc run-out exceeds the specified value, resulting in judder. When the on-the-car type lathe is used, first install a M12 flat washer on the stud bolt in the brake disc side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disc rotor may be deformed, resulting in inaccurate grinding. Grind the brake disc with all wheel nuts diagonally and equally tightened to the specified torque 100 N. m (74 ft-lb). When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disc rotor or drum may be deformed, resulting in judder.
2. If the disc thickness is less than the limits, replace it with a new one. If thickness variation exceeds the specification, turn rotor with an on-the-car type brake lathe ("Accuturn-8750" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disc.

BRAKE DISC RUN-OUT CHECK AND CORRECTION

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1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc. Limit: 0.03 mm (0.0012 inch)
4. If the brake disc run-out exceeds the limit, correct it as follows: Chalk phase marks on the wheel stud and the brake disc, which run-out is excessive as shown. Remove the brake disc. Then place a dial gauge as shown, and measure the end play by pushing and pulling the wheel hub. Limit: 0.05 mm (0.002 inch) If the end play exceeds the limit, disassemble the hub and knuckle assembly to check each part. If the end play does not exceed the limit, dephase the brake disc and secure it. Then recheck the brake disc run-out. CAUTION: After a new brake disc is installed, always grind the brake disc with on-the-car type brake lathe. If this step is not carried out, the brake disc run-out exceeds the specified value, resulting in judder. When the on-the-car type lathe is used, first install a M12 flat washer on the stud bolt in the brake disc side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disc rotor may be deformed, resulting in inaccurate grinding. Grind the brake disc with all wheel nuts diagonally and equally tightened to the specified torque 100 N. m (74 ft-lb). When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disc rotor or drum may be deformed, resulting in judder.
5. If the run-out cannot be corrected by changing the phase of the brake disc, replace the brake disc or grind it with the on-the-car type brake lathe ("Accuturn-8750" or equivalent).

MASTER CYLINDER FUNCTION CHECK

1. Remove the reservoir cap and diaphragm.
2. While watching the open reservoir from a distance of 50 cm (20 inches), have an assistant depress the brake pedal. If there was a stream of brake fluid rising from the reservoir, proceed to Step 3. If there was no stream of brake fluid rising from the reservoir, repair or replace the master cylinder.
3. While watching the open reservoir from a distance of 50 cm (20 inches), have the assistant release the brake pedal. If there was a small amount of air bubbles rising through the brake fluid, master cylinder function is normal. If there were no bubbles rising through the brake fluid, repair or replace the master cylinder.

Scheme 119

>> A << BRAKE PEDAL ASSEMBLY INSTALLATION

Tighten the brake booster mounting nuts (A), and then the brake pedal assembly mounting bolts (B).

Note. The brake pedal assembly cannot be positioned correctly if the brake pedal assembly mounting bolts (B) are tightened first, as the their holes are oblong holes.

Scheme 120

Scheme 121

1. Connect an ohmmeter between the stoplight switch connector terminals.
2. There should be no continuity between the terminals when the plunger is pushed in as shown. There should be continuity when it is released.

Scheme 122

Required Special Tool

1. MB991568: Push Rod Adjusting Socket

>> A << BRAKE BOOSTER VACUUM HOSE CONNECTION

Insert the brake booster vacuum hose to the brake booster assembly with its paint mark facing upward, and then secure the hose by using the hose clip.

Scheme 123

Scheme 124

1. Measure dimension (A). Standard value (A): 8.98 - 9.23 mm (0.354 - 0.363 in) NOTE: When a negative pressure of 66.7 kPa (19.7 inHg) is applied to the brake booster, the push rod should protrude 10.27 - 10.53 mm (0.404 - 0.414 in).
2. If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use special tool MB991568 to turn the push rod while holding the rod spline with angle-nose pliers.

Scheme 125

INSPECTION

1. Check the inner surface of master cylinder body for rust or pitting.
2. Check the primary and secondary pistons for rust, scoring, wear or damage.
3. Check the diaphragm for cracks and wear.

REMOVAL AND INSTALLATION

Scheme 126

>> A << DISC BRAKE ASSEMBLY INSTALLATION

1. Find the drag force of the disc brake (Refer to «FRONT DISC BRAKE PAD CHECK AND REPLACEMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__front-disc-brake-pad-check-and) ). Standard value: 69 N (15 pound) or less
2. If that drag force exceeds the standard value, disassemble the caliper assembly. Then check the piston for contamination or rust, and confirm if the piston or the piston seal is deteriorated.

BRAKE DISC CHECK

Disc wear (Refer to DISC BRAKE ROTOR CHECK .)

Disc run-out (Refer to BRAKE DISC RUN-OUT CHECK AND CORRECTION .)

DISASSEMBLY AND ASSEMBLY

Scheme 127

DISASSEMBLY SERVICE POINTS

<< A >> PISTON BOOT/PISTON REMOVAL

Scheme 128

<< B >> PISTON SEAL REMOVAL

1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.

1. Check the cylinder for wear, damage or rust.
2. Check the piston surface for wear, damage or rust.
3. Check the caliper body for wear.
4. Check the pad for damage or adhesion of grease, check the backing metal for damage.

PAD WEAR CHECK

Measure thickness at the thinnest, most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value.

Standard value: 10.0 mm (0.39 inch)

Minimum limit: 2.0 mm (0.08 inch)

Scheme 129

Scheme 130

1. Find the drag force of the disc brake (Refer to «FRONT DISC BRAKE PAD CHECK AND REPLACEMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer-evolution__front-disc-brake-pad-check-and) ). Standard value: 69 N (15 pound) or less
2. If that drag force exceeds the standard value, disassemble the caliper assembly. Then check the piston for contamination or rust, and confirm if the piston or the piston seal is deteriorated.

Disc wear: Refer to DISC BRAKE ROTOR CHECK .

Disc run-out: Refer to BRAKE DISC RUN-OUT CHECK AND CORRECTION .

Scheme 131

Remove the pistons by pumping in air slowly from the brake hose connection. Be sure to use a wood block and adjust the height of the two pistons while so that the pistons protrude evenly.

Scheme 132

1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with alcohol or brake fluid DOT 3 or DOT 4.

1. Check the cylinder for wear, damage or rust.
2. Check the piston surface for wear, damage or rust.
3. Check the caliper body for wear.
4. Check the pad for damage or adhesion of grease, check the backing metal for damage.

Measure thickness at the thinnest, most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value.

Standard value: 9.0 mm (0.35 inch)

Minimum limit: 2.0 mm (0.08 inch)

Scheme 133

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

LUBRICANTS

LUBRICANTS SPECIFICATIONS

SEALANT

SEALANT SPECIFICATIONS

See also:
• PARKING BRAKE LINING AND DRUM
• 1
• BRAKE DISC RUN-OUT CHECK AND CORRECTION
• DISC BRAKE ROTOR CHECK
• SYMPTOM CHART
• BLEEDING
• CHECK VALVE OPERATION CHECK
• FRONT DISC BRAKE PAD CHECK AND REPLACEMENT
• MASTER CYLINDER FUNCTION CHECK