Basic Brake System - Lancer Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

The brake system offers high dependability and durability along with improved braking performance and brake sensitivity.

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INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS

Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster and drum brake. 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

Scheme 4

1. STEP 1. Check for oil, water, etc., on the pad or lining contact surface of all brakes. Q: Is oil, water, etc., on the pad or lining contact surface? YES : Replace the part and determine and repair source/cause of foreign material. Then go to Step 8 . NO : Go to Step 2 .
2. STEP 2. Check the lining and brake drum contact. Put chalk on the inner surface of the brake drum. Rub the lining against the drum inner surface. NOTE: Clean off chalk after check. Q: Does the lining wipe off or smudge the chalk across the full width of the lining? YES : Go to Step 3 . NO : Replace the shoe and lining assemblies on both sides. Then go to Step 4 .
3. STEP 3. Check the auto adjuster function. Refer to «AUTO ADJUSTER FUNCTION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is there fault? YES : Repair it. Then go to Step 8 . NO : Go to Step 4 .
4. STEP 4. Check the brake drum inside diameter. Refer to «BRAKE DRUM INSIDE DIAMETER CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__brake-drum-inside-diameter-check) . Q: Is the brake drum inside diameter outside of specifications? YES : Replace the part. Then go to Step 8 . NO : Go to Step 5 .
5. STEP 5. 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 6 . NO : Disassemble and inspect the brake assembly (Refer to «DISASSEMBLY AND ASSEMBLY < 2.0 L >»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) ). Then go to Step 8 .
6. STEP 6. Check brake disc(s) for run out. Refer to «FRONT BRAKE DISC RUN-OUT CHECK AND CORRECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is runout outside of specifications? YES : Repair and replace the brake disc(s) as necessary. Then go to Step 8 . NO : Go to Step 7 .
7. STEP 7. Check brake discs for correct thickness. Refer to «BRAKE DISC THICKNESS CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is the thickness outside of specifications? YES : Repair or replace the brake discs(s) as necessary. Then go to Step 8 . NO : Go to Step 8 .
8. STEP 8. 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 «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__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 and determine 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 extend slowly and smoothly with no jumpiness. Repeat for each disc brake assembly. Q: Do the piston move correctly? YES : Go to Step 3 . NO : Disassemble and inspect the brake assembly (Front: refer to «DISASSEMBLY AND ASSEMBLY < 2.4 L >»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) , Rear: refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) ). Then go to Step 5 .
3. STEP 3. Check brake discs for runout. Refer to «FRONT BRAKE DISC RUN-OUT CHECK AND CORRECTION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . 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 «BRAKE DISC THICKNESS CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is the thickness outside of specifications? YES : Repair or replace the brake disc(s) as necessary. Then go to Step 5 . NO : Perform 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__symptom-chart) .

Scheme 5

1. STEP 1. Check whether the brake fluid is low, is the correct fluid (A/T fluid, engine oil, etc.) or is contaminated (debris, sand, etc.). 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__bleeding) ). Then go to Step 9 . 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__bleeding) .). Then go to Step 9 . NO : Go to Step 3 .
3. STEP 3. Check the lining and brake drum contact. Put chalk on the inner surface of the brake drum. Rub the lining against the drum inner surface. NOTE: Clean off chalk after check. Q: Does the lining wipe off or smudge the chalk across the full width of the lining? YES : Go to Step 5 . NO : Replace the shoe and lining assemblies on both sides. Then go to Step 9 .
4. STEP 4. Check the auto adjuster function. Refer to «AUTO ADJUSTER FUNCTION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is there fault? YES : Repair it. Then go to Step 9 . NO : Go to Step 5 .
5. STEP 5. Check the brake booster function. Refer to «BRAKE BOOSTER OPERATING TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is there fault? YES : Replace the part. Then go to Step 9 . NO : Go to Step 6 .
6. STEP 6. Check for pinched or restricted brake tube or hose. Q: Is there pinched or restricted brake tube or hose? YES : Replace that complete section of brake tube or brake hose. Then go to Step 9 . NO : Go to Step 7 .
7. STEP 7. Check for oil, water, etc., on the pad or lining contact surfaces of all brakes. Q: Is oil, water, etc., on the pad or lining contact surface? YES : Replace the part and determine and repair source/ cause of foreign material. Retest the system. Then go to Step 9 . NO : The procedure is complete. If condition persists, go to Step 8 .
8. STEP 8. Check the proportioning valve operation. Refer to «PROPORTIONING VALVE FUNCTION TEST»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__check-valve-operation-check) . Q: Is there fault? YES : Replace the part. Then go to Step 9 . NO : Go to Step 9 .
9. STEP 9. Retest the system. 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__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 a 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__bleeding) ). Then go to Step 6 . 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 the booster vacuum reserve. With the brake pedal fully released, depress the brake pedal slowly until it stops. With a measuring device (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__bleeding) ). Then go to Step 6 . 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) . Q: Is there a fault? YES : Replace the brake booster. Then go to Step 6 . 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 6 . 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 and determine the source/cause of foreign material. Then go to Step 6 . NO : The procedure is complete.
6. STEP 6. Retest the system. 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__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__bleeding) .) Then go to Step 8 . NO : Go to Step 2 .
2. STEP 2. Check the pad or lining for wear. Refer to «BRAKE LINE BLEEDING»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__brake-line-bleeding) or «BRAKE LINING THICKNESS CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__brake-lining-thickness-check) . Q: Is the pad or lining thickness outside of specifications? YES : Replace the part. Then go to Step 8 . 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__check-valve-operation-check) . Q: Is there damage? YES : Replace the part. Then go to Step 8 . 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__master-cylinder-function-check) . Q: Is there fault? YES : Repair it. Then go to Step 8 . 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 8 . NO < Vehicles with rear drum brakes > : Go to Step 6 . NO < Vehicles with rear disc brakes > : Go to Step 7 .
6. STEP 6. Check the auto adjuster function. < Vehicles with rear drum brakes > Refer to «AUTO ADJUSTER FUNCTION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is there fault? YES : Repair the part. Then go to Step 8 . NO : Go to Step 7 .
7. STEP 7. Check the clearance (too much) between the push rod and primary piston. Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is the clearance outside of specifications? YES : Adjust the clearance. Then go to Step 8 . NO : Go to Step 8 .
8. STEP 8. Retest the system. 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__symptom-chart) .

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1. STEP 1. Check the parking brake lever return. Q: Is there fault? YES : Repair it. Then go to Step 9 . NO : Go to Step 2 .
2. STEP 2. Check the parking brake pull amount. Refer to On-vehicle Service - «PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/parking-brake-system/#parking-brakes-lancer) . Q: Is there fault? YES : Adjust it. Then go to Step 9 . NO : Go to Step 3 .
3. STEP 3. 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 4 .
4. STEP 4. Check the amount of grease at each sliding section. Refer to «REAR DRUM BRAKE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is the grease amount low? YES : Apply grease. 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 «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . 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) . 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. Retest the system. 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__symptom-chart) .

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Scheme 9

1. STEP 1. Check the parking brake operating lever return. Q: Is the operation faulty? YES : Repair 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) . Q: Is the grease amount low? YES : Apply grease. Then go to Step 9 . NO : Go to Step 4 .
4. STEP 4. Check the parking brake pull amount. Refer to On-vehicle Service - «PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/parking-brake-system/#parking-brakes-lancer) . Q: Is there a fault? YES : Adjust it. Then go to Step 9 . NO : Go to Step 5 .
5. STEP 5. Check for insufficient clearance between the push rod and primary piston. Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is there a 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) . 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: Does any wheel stick? YES : Inspect that brake assembly. Then go to Step 9 . NO : Go to Step 9 .
9. STEP 9. Retest the system. 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__symptom-chart) .

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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 drums or 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. Retest the system. 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__symptom-chart) .

1. STEP 1. Check the brake drums and lining or brake disc and pads for wear or cutting. Q: Is there wear or cutting? YES : Repair or replace the part. Then go to Step 7 . 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 7 . NO : Go to Step 3 .
3. STEP 3. Check the lining parts for damage. Q: Is there damage? YES : Repair or replace the part. Then go to Step 7 . NO : Go to Step 4 .
4. STEP 4. Check whether the lining is dirty or greasy. Q: Is the lining dirty or greasy? YES : Clean or replace the part. Then go to Step 7 . NO : Go to Step 5 .
5. STEP 5. Check whether the shoe hold-down springs are weak or the shoe-hold-down pins and springs are loose or damaged. Q: Is there fault? YES : Repair or replace the part. Then go to Step 7 . NO : Go to Step 6 .
6. STEP 6. 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) or «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Are the brake pedal and the brake booster pushrod adjusted correctly? YES : Adjust the brake pedal and the brake booster pushrod. Then go to Step 7 . NO : Go to Step 7 .
7. STEP 7. Retest the system. 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__symptom-chart) .

Scheme 13

1. STEP 1. Check whether the backing plate is bent or loose and interfering with the drum. < Vehicles equipped with rear drum brakes > If equipped with rear disc brakes, go to Step 4 . 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-to-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 it. 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 it. Then go to Step 10 . NO : Go to Step 7 .
7. STEP 7. Check the wheel bearings for deterioration or damage, and the grease quality and quantity. Q: Are the wheel bearings damaged or out of grease? YES : Apply grease or replace the part. Then go to Step 10 . NO : Go to Step 8 .
8. STEP 8. Check whether the brake booster, master cylinder or wheel cylinder return is insufficient. Q: Is the brake booster, master cylinder or wheel 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) or «MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . Q: Is the adjustment value come? YES : Adjust. Then go to Step 10 . NO : Go to Step 10 .
10. STEP 10. Recheck symptom. Q: Is the symptom eliminated? YES : Diagnosis 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__symptom-chart) .

Scheme 14

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 100 +/- 10 N.m (74 +/- 7 ft-lb) for the front caliper. Tighten to 60 +/- 5 N.m (45 +/- 3 ft-lb) for the rear caliper. Then go to Step 5 . NO : Go to Step 4 .
4. STEP 4. Check the wheel bearings for wear, damage or dryness. Q: Is there fault? YES : Apply grease or replace the part. Then go to Step 5 . NO : 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 surfaces, refer to the «SYMPTOM CHART»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__symptom-chart) .

SPECIAL TOOLS

SPECIAL TOOLS DESCRIPTION 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 A: MB990520 Disc brake piston expander B: MB990619 Installer MB990619-01 or general service tool Pushing-in of the disc brake piston Installation of the drum brake wheel cylinder piston cup MB990998 Front hub remover and installer MB990998-01 Provisional holding of the wheel bearing

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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. If the brake pedal height is not within the standard value, follow the procedure below. Remove the brake booster (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) ). 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 (0.09in). Install the brake booster (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) ). 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). Screw in the stop light switch until its thread contacts the stopper, and fix the stop light switch by turning it approximately one quarter of a turn clockwise. Check that the clearance between the stop light switch and the stopper is as shown. Connect the connector at the stoplight switch. CAUTION: Check that the stop lamp does not illuminate when the brake pedal is not depressed.
4. For A/T models, check the key interlock and shift lock mechanisms. < Refer to «KEY INTERLOCK MECHANISM CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/automatic-trans/#on-vehicle-service-diagnosis-with-20l__key-interlock-mechanism-check) . (2.0L) or «FLUSHING COOLERS AND TUBES»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/automatic-trans/#on-vehicle-service-diagnosis-with-24l__flushing-coolers-and-tubes) . (2.4L) >
5. Return the carpet, etc.

Scheme 20

BRAKE PEDAL FREE PLAY

1. Turn the ignition switch to the "LOCK" (OFF) position, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range. Standard value: 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
3. Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod

1. Brake pedal height
2. Installation position of the stoplight switch, etc.

Scheme 21

CLEARANCE BETWEEN BRAKE PEDAL AND FLOORBOARD

1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with approximately 490 N (110 pound) 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 melting sheet (floorboard) to the face of pedal pad]
3. If the clearance is outside the standard value, check for air trapped in the brake line, thickness of the disc brake pad, clearance between the lining and the drum and dragging in the parking brake. And then adjust and replace defective parts as required.
4. Return the carpet etc. to its original position.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

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 (Refer to «CHECK VALVE OPERATION CHECK»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer__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 booster and repeat this test starting at Step 1.

CHECK VALVE OPERATION CHECK

1. Remove the vacuum hose. (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) .) CAUTION: If the check valve is defective, replace it as an assembly unit together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum pump.

VACUUM PUMP CONNECTION SPECIFICATION

Scheme 26

PROPORTIONING VALVE FUNCTION TEST < VEHICLES WITHOUT ABS >

Scheme 27

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__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: 3.19 - 3.67 MPa (463 - 532 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 (995psi). Standard value: 4.17 - 4.66 MPa (605 - 676 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 (73psi)
6. If the measured pressure exceeds the limit, replace the proportioning valve.

Scheme 28

BLEEDING

MASTER CYLINDER BLEEDING

The master cylinder used 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.)

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.

Scheme 29

BRAKE LINE BLEEDING

Start the engine and bleed the air in the sequence shown in the figure.

Scheme 30

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 31

FRONT DISC BRAKE PAD CHECK AND REPLACEMENT

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.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. Check the brake pad thickness through the caliper body check port. Standard value: 10.0 mm (0.39 inch) Minimum limit: 2.0mm (0.08 inch) CAUTION: Do not wipe off the special grease that is on the slide pin or allow it to contaminate the slide pin.
2. Remove the front brake bolt/rear brake pin (lock pin). Pivot the caliper assembly and hold it with wires.
3. Remove the following parts from caliper support. Pad and wear indicator assembly or pad assembly Pad assembly Front brake clip/rear brake clip Inner shim Outer shim
4. In order to measure the brake drag force after pad installation, measure the rotary-sliding resistance of the hub with the pads removed. For the front brakes, refer to «FRONT DISC BRAKE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . For the rear brakes, refer to «REAR DISC BRAKE ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) .
5. Install the pads and caliper assembly, and then check the brake drag force. For the front brakes, refer to «FRONT DISC BRAKE ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) . For the rear brakes, refer to «REAR DISC BRAKE ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) .

DISC BRAKE ROTOR CHECK

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

ITEM REMARKS CHART

Scheme 36

1. Using a micrometer, measure disc thickness at eight positions, approximately 45 degrees apart and 10 mm (0.4 inch) in from the outer edge of the disc. Standard value: < Front > 26.0 mm (1.02 inch) < Rear > 10.0 mm (0.39 inch) Minimum limit: < Front > 24.4 mm (0.96 inch) < Front > 8.4 mm (0.33 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 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.

Scheme 37

Scheme 38

Scheme 39

Scheme 40

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: 0.04 mm (0.0015 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 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 ("MAD, DL-8700PF" or equivalent).

BRAKE LINING THICKNESS CHECK

1. Remove the brake drum.
2. Measure the thickness of the brake lining at the area with the worst wear. Standard value: 4.3 mm (0.17 inch) Minimum limit: 1.0 mm (0.04 inch)
3. Replace the shoe and lining assembly if the brake lining thickness is less than the limit or if it is not worn evenly. For installation procedures for the shoe and lining assembly, Refer to «REAR DRUM BRAKE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) .

Scheme 41

BRAKE DRUM INSIDE DIAMETER CHECK

1. Remove the brake drum.
2. Measure the inside diameter of the brake drum at two or more locations. Standard value: 203 mm (7.99 inches) Limit: 205 mm (8.07 inches)
3. Replace the brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalance.

Scheme 42

BRAKE LINING AND BRAKE DRUM CONTACT CHECK

1. Remove the brake drum.
2. Remove the shoe and lining assembly. (Refer to «REAR DRUM BRAKE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical-hydraulic/#basic-brake-system-lancer) .)
3. Chalk the inner surface of the brake drum and rub with the shoe and lining assembly.
4. Replace the shoe and lining assembly or brake drums if there are any irregular contact areas.

Note. Clean off chalk after check.

Scheme 43

Scheme 44

Scheme 45

1. Remove the brake drum.
2. Operate the parking brake lever. Observe adjuster lever movement for ratcheting action of the auto adjuster. Repair or replace the lever(s) as required.
3. Remove the shoe-to-lever spring.
4. Remove the adjuster. NOTE: It may be necessary to rotate the adjuster wheel bottom to top to release tension.
5. Inspect the adjuster wheel for wear, i.e., flat spots, worn teeth, etc. Replace if faulty.
6. Check both ends of the adjuster for smooth rotation. Replace if faulty.
7. Apply brake grease SAE J310, NLGI number 1 as shown.
8. To install adjuster, assemble the adjuster so it is at its minimum length and insert between shoe and lining assemblies.
9. Install adjuster lever and shoe-to-lever spring.
10. Rotate the adjuster wheel top to bottom until the drum has a slight drag when the drum is installed.

Scheme 46

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 47

>>A<< BRAKE PEDAL AND PEDAL SUPPORT MEMBER INSTALLATION

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

Note. The pedal support member can not be positioned correctly if the pedal mounting bolts (B) are tightened first as the their holes are oblong holes.

Scheme 48

STOPLIGHT SWITCH CHECK

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 49

Scheme 50

Required Special Tool

1. MB991568: Push Rod Adjusting Socket

>>A<< VACUUM HOSE CONNECTION

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

Scheme 51

1. Measure dimension (A). Standard value (A): < 2.0 L > 9.18 - 9.43 mm (0.361 - 0.371 in) < 2.4 L > 9.68 - 9.92 mm (0.381 - 0.390 in) NOTE: When a negative pressure of 66.7 kPa is applied to the brake booster, the push rod should protrude 10.28 -10.53 mm (0.405 - 0.415 in).
2. If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use the special tool MB991568 to turn the push rod while holding the rod spline with angle-nose pliers.

Scheme 52

Scheme 53

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 crack and wear

Scheme 54

>>A<< DISC BRAKE ASSEMBLY INSTALLATION

1. In order to measure the brake drag torque, measure the hub torque with the pads removed by the following procedure. Remove the driveshaft. (Refer to «DRIVESHAFT ASSEMBLY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/axle-shafts/#front-axle-lancer) .) Attach special tool MB990998 to the front hub assembly as shown in the illustration, and tighten it to the specified torque. Tightening torque: 245 +/- 29 N.m (181 +/- 21 ft-lb) Use a spring scale to measure the hub torque in the forward direction. Record hub torque with pads removed. CAUTION: Do not let any oil, grease or other contamination get on to the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool MB990520.
4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and installing the slide pin.
5. Check the brake drag force as follows. Start the engine and hold the brake pedal down for 5 seconds. [Pedal depression force: approximately 200 N (45 pound)] Stop the engine. Turn the brake disc forward 10 times. Use a spring scale to measure the hub torque with pads installed in the same direction as earlier. Calculate the drag force of the disc brake [difference between hub torque with pads installed and hub torque with pads removed]. Standard value: 78 N (17 pound) or less
6. If the brake drag force exceeds the standard value, disassemble and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.

Scheme 55

Scheme 56

Scheme 57

BRAKE DISC CHECK

Disc wear (Refer to BRAKE DISC THICKNESS CHECK .)

Disc run-out (Refer to BRAKE DISC THICKNESS CHECK .)

Scheme 58

Scheme 59

DISASSEMBLY SERVICE POINTS

When disassembling the disc brakes, disassemble both sides (left and right) as a set.

<< A >> PISTON BOOT/PISTON REMOVAL

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose to remove the piston boot and piston.

Scheme 60

<< B >> PISTON SEAL REMOVAL

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

Scheme 61

Scheme 62

Scheme 63

When disassembling the disc brakes, disassemble both sides (left and right) as a set.

<< A >> PISTON BOOT/FRONT BRAKE CALIPER PISTON REMOVAL

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose to remove the piston boot and piston.

Scheme 64

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

Scheme 65

1. Check the cylinder for wear, damage or rust.
2. Check the piston surface for wear, damage or rust.
3. Check the caliper body or sleeve 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 and 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 66

Scheme 67

<< A >> RETAINER REMOVAL

Use a flat-tipped screwdriver or a similar tool to open up the retainer joint. Then remove the retainer.

Scheme 68

>>A<< WAVE WASHER INSTALLATION

Install the wave washer in the direction shown in the illustration.

Scheme 69

>>B<< RETAINER INSTALLATION

Use pliers or a similar tool to close the retainer end onto the pin.

Scheme 70

Scheme 71

Scheme 72

1. Assemble the shoe and lever assembly, the adjuster lever, the shoe and lining assembly, the shoe-to-lever spring, the automatic adjuster assembly temporarily.
2. Depress the wheel cylinder piston by hand.
3. Install the assembly to the backing plate carefully.

Scheme 73

Refer to BRAKE DRUM INSIDE DIAMETER CHECK .

Refer to BRAKE DRUM INSIDE DIAMETER CHECK .

Refer to BRAKE DRUM INSIDE DIAMETER CHECK .

Scheme 74

>>A<< PISTON CUP/PISTON ASSEMBLY

1. Use alcohol or brake fluid DOT 3 or DOT 4 to clean the wheel cylinder and the piston.
2. Apply brake fluid DOT 3 or DOT 4 to the piston cups and special tool MB990619. CAUTION: In order to keep the piston cup from becoming twisted or slanted, slide the piston cup down special tool MB990619 slowly and carefully, without stopping.
3. Set the piston cup on special tool MB990619 with the lip of the cup facing up. Fit the cup onto special tool MB990619, and then slide it down the outside of special tool MB990619 into the piston groove.

Scheme 75

Check the piston and wheel cylinder walls for rust, pitting, or damage. If there is any abnormality, replace the entire wheel cylinder assembly.

Scheme 76

Scheme 77

1. In order to measure the brake drag torque, measure the hub torque with the pads removed by the following procedure. Use a spring scale to measure the hub torque in the forward direction. Record hub torque with pads removed. CAUTION: Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the backing plate, install the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool MB990520.
4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and installing the lock pin.

Scheme 78

>>B<< BRAKE DRAG FORCE CHECK

1. Check the brake drag force as follows. Start the engine and hold the brake pedal down for 5 seconds. [Pedal depression force: approximately 200 N (45 pound)] Stop the engine. Turn the brake disc forward 10 times. Use a spring scale to measure the hub torque with pads installed in the same direction as earlier. Calculate the drag force of the disc brake [difference between hub torque with pads installed and hub torque with pads removed]. Standard value: 68 N (15 pounds) or less
2. If the brake drag force exceeds the standard value, disassemble and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.

Disc wear (Refer to BRAKE DISC THICKNESS CHECK ).

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

Scheme 79

Scheme 80

Scheme 81

When disassembling the disc brakes, disassemble both sides (left and right) as a set.

<< A >> REAR BRAKE CALIPER PISTON/PISTON BOOT REMOVAL

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air through the brake hose to remove the piston boot and piston.

Scheme 82

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

Scheme 83

Refer to DISASSEMBLY SERVICE POINTS .

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

LUBRICANTS

LUBRICANTS SPECIFICATION

SEALANT

SEALANT SPECIFICATION

See also:
• PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT
• KEY INTERLOCK MECHANISM CHECK
• FLUSHING COOLERS AND TUBES
• DRIVESHAFT ASSEMBLY
• 1
• BRAKE DRUM INSIDE DIAMETER CHECK
• SYMPTOM CHART
• BLEEDING
• PROPORTIONING VALVE FUNCTION TEST
• BRAKE LINE BLEEDING
• BRAKE LINING THICKNESS CHECK
• MASTER CYLINDER FUNCTION CHECK