Disc - Evolution Mitsubishi Lancer Evolution VIII

DESCRIPTION

The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. For configuration diagram (Scheme 40)

Scheme 40

The parking brakes are a mechanical rear wheel brake design and controlled by a lever.

BLEEDING BRAKE SYSTEM

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 line will become easier.

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.

BRAKE LINE BLEEDING

Start engine, and bleed system in the following sequence: RR, LF, LR, RF.

Scheme 41

Scheme 42

Scheme 43

1. Turn up the carpet etc. under the brake pedal. Measure the brake pedal height as illustrated. (Scheme 41)
2. If distance between surface of floorboard to face of pedal pad is not 6.7-6.8" (169.1-172.1 mm), adjust as follows: Disconnect the stoplight switch connector. Remove brake booster. See «POWER BRAKE BOOSTER»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution) under REMOVAL & INSTALLATION. Adjust brake pedal height by turning the clevis. (Scheme 42) NOTE: When the clevis is turned 180 degrees, the pedal height is changed by approximately.09" (2.4 mm). Install brake booster. Measure brake pedal height again. If brake pedal height is not within specification, go to step b. Screw in the stop light switch until its thread contacts the stopper. Turn the stoplight switch 1/4 turn clockwise to secure. Turn the stoplight switch 1/4 turn clockwise to secure. Confirm that the clearance between the switch plunger and the stopper is as shown in illustration. (Scheme 43) Connect the connector of the stoplight switch. Check to be sure that the stoplight does not illuminated with the brake pedal released.
3. Return the carpet, etc. to its original position.

BRAKE PEDAL FREE PLAY

1. Turn ignition switch to "LOCK" (OFF) position. Depress brake pedal 2 or 3 times. After eliminating vacuum in brake booster, press pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is .12-.31" (3-8 mm).
2. If brake pedal free 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 44

1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with approximately 110 lbs. (490 N) of force, and measure the clearance between the brake pedal and the floorboard. (Scheme 44)
3. If clearance is not 3.5" (90 mm) or more, check for air trapped in the brake line, thickness of the disc brake pad, clearance between brake lining and brake drum, and dragging in the parking brake. Adjust or replace defective parts as required.
4. Return the carpet etc. to its original position.

Scheme 45

Scheme 46

1. Measure protruding length "A" at the pushrod. (Scheme 45) Push rod protruding length should be.354-.363" (8.98-9.23 mm). NOTE: When a negative pressure of 19.6 in. Hg is applied to the brake booster, push rod protruding length should be.404-.415" (10.27-10.53 mm).
2. If the protruding length is not as specified, change pushrod length by turning the end of the pushrod using Push Rod Adjusting Socket (MB991568) while holding rod spline with angle-nose pliers. (Scheme 46)

Scheme 47

1. Pull the parking brake lever with a force of approximately 45 lbs. (200 N) and count the number of notches.
2. Parking brake lever stroke should be 5-7 notches. If parking brake lever stroke is not as specified, adjust as described below. Remove rear floor console assembly. Loosen the adjusting nut to move it to the cable rod end so that the cable will be free. (Scheme 47) Remove rear wheels. Remove rear wheel hub plug, and use a flat-tipped screwdriver to turn shoe slack adjuster in direction which expands shoes so that disc will not rotate. Turn shoe slack adjuster 4 notches in the opposite direction. Turn adjusting nut to adjust parking brake lever stroke. After adjusting, ensure that there is no space between adjusting nut and parking brake lever. Ensure adjusting nut is secured with nut holder. CAUTION: If parking brake lever stroke is less than specification and brake pedal is too firm, rear brakes may drag. After adjusting parking brake lever stroke, release parking brake and turn rear wheels to ensure rear brakes are not dragging.

BRAKE FLUID LEVEL SENSOR

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

P4ARKING BRAKE SWITCH

Remove floor console. Remove right front seat. Check continuity between parking brake switch terminal and switch mounting bolt. (Scheme 48) When parking brake lever is pulled, resistance should be less than 2 ohms. When parking brake lever is released, circuit should be open.

Scheme 48

System Check

1. Run engine for 1-2 minutes. Shut engine off, and depress brake pedal several times with normal pressure. If pedal height gradually becomes higher with successive applications, power brake booster is okay. If pedal height remains steady, power brake booster is not operating properly. Go to next step.
2. With engine stopped, depress brake pedal repeatedly until pedal height no longer falls. Hold brake pedal down, and start engine. If pedal moves downward slightly, power brake booster is okay. If pedal height does not change, power brake booster is not operating properly. Go to next step.
3. With engine running, press and hold brake pedal. Shut off engine. Hold brake pedal for 30 seconds. Brake pedal height should not change. If pedal rises, power brake booster is not operating properly. Go to next step.
4. If brake booster operation is not as specified in each step, disconnect vacuum hose at brake booster, and check for sufficient vacuum with engine running. Check brake booster check valve operation. Repair or replace as necessary.

Check Valve Inspection

Remove vacuum hose from power brake booster. DO NOT remove check valve from hose. Check valve should hold vacuum in one direction and allow air to pass in other direction. Negative pressure should be created and held when vacuum is connected on brake booster side.

PROPORTIONING VALVE (VEHICLES WITHOUT ABS)

Scheme 49

1. Connect two pressure gauges to the output port of the master cylinder and output port of the proportioning valve. (Scheme 49)
2. Bleed brake system and gauges. See «BLEEDING BRAKE SYSTEM»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution__bleeding-brake-system).
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 392-462 psi (2770-3190 kPa).
4. Depress the brake pedal more strongly than at the above step. Then check that the output fluid pressure is 534-604 psi (3680-4170 kPa) when input fluid pressure is 995 psi (6860 kPa).
5. Measure each output fluid pressure at both valves, and check that the difference between the two is 73 psi (500 kPa) or less. If the measured pressure exceeds the limit, replace the proportioning valve.

FRONT DISC BRAKE PADS

Removal & Installation

1. Raise and support vehicle. Remove front wheels. While holding caliper cross spring, pull pins out of caliper. (Scheme 53) Remove shims and pads from caliper.
2. If installing new pads, compress piston to bottom of bore using Disc Brake Piston Expander (MB990520). Apply repair kit grease to sides of pads. Ensure grease is not applied to any other surfaces. Install brake pads and pins. Start engine and depress brake pedal several times to expand caliper piston. Check brake fluid level.

Removal

Raise and support vehicle. Remove front wheels. Remove hose clip from brake hose mount (if equipped). Disconnect brake hose from caliper. Remove upper and lower caliper-to-steering knuckle bolts. Remove caliper.

Installation

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

Raise vehicle, and remove wheel(s). Remove caliper. See FRONT BRAKE CALIPER . Slide rotor off hub. To install, reverse removal procedure.

Drain brake fluid from master cylinder. Remove air cleaner and air intake hose. Remove strut tower bar. Disconnect brake fluid level sensor connector. Disconnect brake lines from master cylinder, and install plugs to prevent brake fluid spillage. Remove master cylinder-to-booster nuts, and remove master cylinder.

To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS . After installation, adjust pedal height. See BRAKE PEDAL HEIGHT under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM .

Scheme 50

1. (Scheme 50)for removal and installation. Remove rear floor console and rear console bracket. Remove rear seat cushion.
2. Remove parking brake shoes. See «PARKING BRAKE SHOES»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution).
3. Remove clip and parking brake cable from backing plate. (Scheme 52)
4. Disconnect parking brake cable from parking brake lever. See «PARKING BRAKE LEVER»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution). Remove cable bracket bolts and parking brake cable.
5. To install, reverse removal procedure. Check parking brake lever stroke, and adjust as necessary. See «PARKING BRAKE LEVER STROKE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution) under ADJUSTMENTS.

Scheme 51

1. Remove floor console assembly and rear console bracket. Remove adjusting nut. (Scheme 51) Disconnect parking brake switch connector.
2. Disconnect parking brake cable from parking brake lever. Remove mounting bolts and parking brake lever assembly. Remove parking brake switch from parking brake lever assembly.
3. To install, reverse removal procedure. Check parking brake lever stroke, and adjust as necessary. See «PARKING BRAKE LEVER STROKE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution) under ADJUSTMENTS.

Scheme 52

1. Raise and support vehicle. Remove rear wheels. Remove rear disc brake caliper and rotor. See «REAR BRAKE ROTOR»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution).
2. Remove rear hub. Remove the following: (Scheme 52) Shoe return springs. Shoe guide plate. Shoe auto adjuster spring. Shoe slack adjuster. Parking brake operating lever strut. Shoe-to-strut spring. Shoe spring cup. Shoe hold-down spring. Brake shoe assembly.
3. To install, reverse removal procedure. When installing adjusters, ensure that shoe adjusting bolt on left side is attached toward rear of vehicle and shoe adjusting bolt on right side is attached toward front of vehicle.
4. Ensure Yellow shoe return spring is installed on rear side and Blue shoe return spring is installed on front side.
5. Check parking brake lever stroke, and adjust as necessary. See «PARKING BRAKE LEVER STROKE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution) under ADJUSTMENTS.
6. Perform parking brake lining seating procedure. See «PARKING BRAKE LINING SEATING PROCEDURE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution__parking-brake-lining-seating-procedure).

PARKING BRAKE LINING SEATING PROCEDURE

Perform lining seating by the following procedure when replacing the parking brake shoe assemblies or the rear brake discs, or when brake performance is insufficient.

1. Adjust the parking brake lever stroke to the standard value. See «PARKING BRAKE LEVER STROKE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/mechanical-hydraulic/#disc-evolution) under ADJUSTMENTS.
2. Hook a spring scale onto the center of the parking brake lever grip and pull it with a force of 22-34 lbs. (100-150 N) in a direction perpendicular to the handle.
3. Drive the vehicle at a constant speed of 22-31 MPH for 328 ft. (100 meters).
4. Release the parking brake and let the brakes cool for 5-10 minutes.
5. Repeat steps 2 - 4 four to five times.

Remove brake master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from power brake booster. Disconnect clevis pin attaching brake pedal to power brake booster push rod. From inside vehicle, remove 4 nuts attaching power brake booster to firewall. Remove power brake booster.

Check brake booster push rod protruding length, and adjust if necessary. See BRAKE BOOSTER PUSH ROD under ADJUSTMENTS. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Install master cylinder. Bleed brake system if necessary.

POWER BRAKE BOOSTER CHECK VALVE

Note. To test check valve before removal, see POWER BRAKE BOOSTER under TESTING.

Loosen clamps, and remove vacuum hose/check valve assembly. Install vacuum hose/check valve assembly with white-marked sections facing up. Insert securely and completely until vacuum hose at engine side contacts edge of hexagonal part of fitting, and then secure with hose clamps.

Raise and support vehicle. Remove rear wheels. Remove pins. (Scheme 54) Remove inner shims, anti-squeak shim and pad assembly from support mounting. Remove pad clips.

If installing new pads, compress piston to bottom of bore. Install retaining clips, pads and shims. Install pins. Start engine and depress brake pedal several times to expand caliper piston. Check brake fluid level.

Raise and support vehicle. Remove rear wheels. Disconnect brake hose from caliper. Cap end of brake line to prevent spillage. Remove upper and lower caliper mounting bolts. Lift caliper body upward. Remove caliper.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .

Raise and support vehicle. Remove rear caliper. See REAR BRAKE CALIPER . Remove rotor. To install, reverse removal procedure.

OVERHAUL

Note. For exploded views of front caliper (Scheme 53) For exploded view of rear caliper (Scheme 54) For exploded view of master cylinder (Scheme 55)

Scheme 53

Scheme 54

Scheme 55

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

BRAKE SPECIFICATIONS

See also:
• POWER BRAKE BOOSTER
• BLEEDING BRAKE SYSTEM
• TORQUE SPECIFICATIONS
• PARKING BRAKE LINING SEATING PROCEDURE