Basic Brake System - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

The 10-inch single brake booster with brake assist mechanism, which determines an emergency exists based on the brake pedal depression speed and force and provides the maximum braking force, has been adopted.

Scheme 1

When the driver suddenly applies the brake, generally there is a tendency that a driver depresses the brake pedal quickly but not strong enough, or depresses the pedal once but reduces the depression force immediately after that. In this case, a sufficient braking force cannot be obtained, resulting in a longer stopping distance.

This brake booster with brake assist mechanism recognizes the status as emergency when the driver depresses the brake pedal quickly; it increases the assist force to the maximum value and maintains the output value of the brake booster to activate ABS.

Even if the driver reduces the depression force immediately after depressing the brake pedal quickly, this brake booster maintains the status where the maximum assist force is being applied until no depression force is applied to the brake pedal.

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

LUBRICANTS

LUBRICANT SPECIFICATIONS

INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS

Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster and disc or drum 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»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__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 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(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 < 15-INCH FRONT DISC BRAKE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) , «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (EXCEPT RALLIART) >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (RALLIART) >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . REAR: refer to «DISASSEMBLY AND ASSEMBLY < 14-INCH REAR DISC BRAKE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) , «DISASSEMBLY AND ASSEMBLY < 16-INCH REAR DISC BRAKE (EXCEPT RALLIART) >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «DISASSEMBLY AND ASSEMBLY < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . Then go to Step 5 .
3. STEP 3. Check brake disc(s) for run-out. Refer to «BRAKE DISC CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . Q: Is run-out 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 CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . 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 «SYMPTOM CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__symptom-chart) .

INSPECTION PROCEDURE 2: Insufficient Braking Power

DIAGNOSIS

Scheme 2

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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__bleeding) ). Then go to Step 8 . 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__bleeding) ). Then go to Step 8 . NO: Go to Step 3.
3. STEP 3. Check the lining and brake drum contact. < Vehicles equipped with rear drum brake > If equipped with rear disc brake, go to Step 5. 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 4. NO: Replace the shoe and lining assemblies on both sides. Go to Step 8 .
4. STEP 4. Check the auto adjuster function. < Vehicles equipped with rear drum brake > Refer to «AUTO ADJUSTER FUNCTION CHECK < VEHICLES WITH REAR DRUM BRAKE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . Q: Is there fault? YES: Repair it. Then go to Step 8 . NO: Go to Step 5.
5. STEP 5. Check the brake booster function. Refer to «BRAKE BOOSTER OPERATION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . Q: Is there fault? YES: Replace the part. Then go to Step 8 . 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 8 . 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. Recheck symptom. Then go to Step 8. NO: The procedure is complete. If condition persists, go to Step 8.
8. STEP 8. 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-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 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__bleeding) ). Then go to Step 6 . NO: Go to Step 2.
2. STEP 2. Check the pad for wear. Refer to «BRAKE PAD CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__brake-pad-check) . Q: Is the pad thickness outside of specifications? YES: Replace the part. Then go to Step 6 . 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) . Q: Is there a damage? YES: Replace the part. Then go to Step 6 . NO: Go to Step 4.
4. STEP 4. Check for brake fluid leaks. Q: Is there a leak? 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 6 . NO: Go to Step 5.
5. STEP 5. Check the master cylinder assembly. Remove the master cylinder assembly (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ). Check for brake fluid leaks from the master cylinder assembly seal. Q: Is a brake fluid leaking from the master cylinder assembly seal present? YES: Replace the master cylinder assembly and the brake booster assembly (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ). 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__symptom-chart) .

Scheme 3

1. STEP 1. Check the parking brake lever return. Q: Is the operation faulty? YES: Repair it. Then go to Step 7 . 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 7 . 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/x-2007-2016/remont/parking-brake-system/#parking-brakes-except-lancer-evolution) < Except RALLIART > or «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/parking-brake-system/#parking-brakes-except-lancer-evolution) < RALLIART >. Q: Is the grease amount low? YES: Apply grease. Then go to Step 7 . NO: Go to Step 4.
4. STEP 4. Check the parking brake pull amount. Refer to «PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/parking-brake-system/#parking-brakes-except-lancer-evolution__parking-brake-lever-stroke-check-and) . Q: Is there a fault? YES: Adjust it. Then go to Step 7 . NO: Go to Step 5.
5. STEP 5. Check port for clogging. Q: Is the port clogged? YES: Repair it. Then go to Step 7 . NO: Go to Step 6.
6. STEP 6. 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 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__symptom-chart) .

1. STEP 1. Check the front brakes, then rear brakes, for metal-to-metal condition. Q: Is any 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 any 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 shield and brake disc < Front >, interference between the backing plate and brake disc < Rear >. Q: Is there any 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 dust shield or backing plate. Q: Is the dust shield or backing plate 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-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 any rust? YES: Remove the rust. Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Adjust the brake pedal. Refer to «BRAKE PEDAL CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__brake-pedal-check-and-adjustment) . Q: Is the brake pedal adjusted correctly? YES: Go to Step 4. NO: Adjust the brake pedal. 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__symptom-chart) .

1. STEP 1. Check whether the backing plate is bent or loose and interfering with the drum. Q: Is there a fault? YES: Replace the part. Then go to Step 8 . 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 any damage? YES: Replace the part. Then go to Step 8 . NO: Go to Step 3.
3. STEP 3. Check the brake drum for wear and the shoe spring for damage. Q: Is there any wear or damage? YES: Replace the part. Then go to Step 8 . 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 8 . NO: Go to Step 5.
5. STEP 5. Check the brake pads for correct installation. Q: Are the pads installed incorrectly? YES: Install the pads correctly. Then go to Step 8 . NO: Go to Step 6.
6. STEP 6. Check the calipers for correct installation. Q: Are the calipers installed incorrectly? YES: Install the calipers correctly. Then go to Step 8 . NO: Go to Step 7.
7. STEP 7. Check the wheel bearings for end play. Refer to «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution__wheel-bearing-end-play-check) < Front >, «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-fwd-except-lancer-evolution) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-awd-except-lancer-evolution) < Rear (AWD) >. Q: Does the measured end play exceed the limit? YES: Replace the faulty hub assembly (Refer to «FRONT AXLE HUB ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution) < Front >, «REAR AXLE HUB ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-fwd-except-lancer-evolution) < Rear (FWD) > or «REAR AXLE HUB ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-awd-except-lancer-evolution) < Rear (AWD) >). Then go to Step 8. NO: Go to Step 8.
8. STEP 8. 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__symptom-chart) .

Scheme 4

Scheme 5

1. STEP 1. Check whether foreign material has entered the wheel covers. Q: Is there any 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. Refer to «WHEEL AND TIRE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/wheel-tire-system/#wheel-and-tire-except-lancer-evolution) . Q: Are the wheel nuts loose? YES: Tighten the wheel nuts to the specified torque (Refer to «WHEEL AND TIRE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/wheel-tire-system/#wheel-and-tire-except-lancer-evolution) ). Then go to Step 5 . NO: Go to Step 3.
3. STEP 3. Check for looseness of the caliper installation bolts. Refer to «FRONT DISC BRAKE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) < Front >, «REAR DISC BRAKE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) < Rear (Except RALLIART) > or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) < Rear (RALLIART) >. Q: Are the caliper installation bolts loose? YES: Tighten the caliper installation bolts to the specified torque (Refer to «FRONT DISC BRAKE ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) < Front >, «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) < Rear> or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) < Rear>. Then go to Step 5 . NO: Go to Step 4.
4. STEP 4. Check the wheel bearings for end play. Refer to «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution__wheel-bearing-end-play-check) < Front >, «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-fwd-except-lancer-evolution) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-awd-except-lancer-evolution) < Rear (AWD) >. Q: Does the measured end play exceed the limit? YES: Replace the faulty hub assembly (Refer to «FRONT AXLE HUB ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution) < Front >, «REAR AXLE HUB ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-fwd-except-lancer-evolution) < Rear (FWD) > or «REAR AXLE HUB ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-awd-except-lancer-evolution) < Rear (AWD) >). 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__symptom-chart) .

SPECIAL TOOLS

SPECIAL TOOLS Tool Number Name Use MB992146 Booster test adapter Inspection using a simplified tester MB990964 MB990520 MB990619 Brake tool set Piston expander Installer Disc brake piston pushing back Installation of the drum brake wheel cylinder piston cup

Scheme 6

BRAKE PEDAL CHECK AND ADJUSTMENT

Scheme 7

Scheme 8

Scheme 9

1. Turn up the floor carpet under the brake pedal.
2. Remove the stoplight switch (Refer to «STOPLIGHT SWITCH CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).
3. Use a needle or similar tool to measure the dimension A in the figure (distance from the dash panel pad surface to the dash panel).
4. Measure the dimension B in the figure (distance from the pedal pad surface to the dash panel pad surface).
5. Make sure that the total of the dimensions A and B measured in Steps 2 and 3 (brake pedal height) is within the standard value. Standard value (A+B): 219.8 - 227.8 mm (8.7 - 9.0 inches)
6. When the brake pedal height is not within the standard value, inspect the brake pedal in the following procedure. Remove the brake pedal assembly (Refer to «BRAKE PEDAL»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ). Check the removed brake pedal assembly for distortion, and replace it when deformed (Refer to «BRAKE PEDAL DISTORTION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ). Install the brake pedal assembly (Refer to «STOPLIGHT SWITCH CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ). NOTE: When installing, compress the dash panel pad. Measure the brake pedal height again, and make sure that it is within the standard value (A+B). When the measured value is not within the standard value, measure the dimension C in the figure (distance from the stud bolt end to the clevis hole center), and make sure it is within the standard value (C). Standard value (C): 75.8 - 80.2 mm (2.98 - 3.16 inches) When the measured value is not within the standard value (C), replace the brake booster (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).
7. After checking the brake pedal height, install the stoplight switch in the following procedure: Pull and hold the brake pedal by hand. Insert the stoplight switch until the stoplight switch body contacts the pedal stopper, then turn the switch approximately one eighth of a clockwise turn to fix it. Check that the clearance between the stoplight switch and the pedal stopper is as shown in the figure. CAUTION: Make sure that the stoplight is not illuminated when the brake pedal is not depressed. Connect the stoplight switch connector.
8. Check the key interlock mechanism and the shift lock mechanism (Refer to «SHIFT LOCK MECHANISM CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#twin-clutch-sportronic-shift-transmission-tc-sst-on-vehicle-service-except-lancer-evolution) < TC-SST > or «SHIFT LOCK MECHANISM CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-on-vehicle-service-except-lancer-evolution) < CVT >).
9. Recover the floor carpet under the brake pedal.

Scheme 10

1. With the engine stopped, depress the brake pedal 2 or 3 times to release the vacuum in the brake booster. Then, press the brake pedal with your finger and check if the pedal stroke until the pedal becomes heavy (play) is within the standard value. Standard value (D): 3 - 8 mm (0.12 - 0.31 inch)
2. When the brake pedal free play is not within the standard value, check the brake pedal-to-clevis pin looseness, clevis pin-to-booster operating rod looseness, brake pedal height, and stoplight switch position, and adjust or replace as necessary.

Scheme 11

1. Turn up the floor carpet under the brake pedal.
2. Start the engine and depress the brake pedal with approximately 500 N, and measure clearance between the brake pedal and the floor panel. Standard value (E): 85 mm (3.35 inches) or more
3. When the clearance is not within the standard value, check for air in the brake line and thickness of the disc brake pad, and correct or replace as necessary.
4. Recover the floor carpet under the brake pedal.

Scheme 12

Scheme 13

Scheme 14

1. Carry out the simplified brake booster operation check in the following procedure: Run the engine for 1 to 2 minutes, and then stop. Depress the brake pedal with normal depression force. The result is judged as "Good" when the pedal stroke is great at the first depression, and becomes smaller as you repeat depressing the pedal. If the pedal stroke does not change, the result is judged as "No Good." With the engine stopped, depress the brake pedal several times. Keep the brake pedal depressed and start the engine. At this time, when the pedal moves down slightly, the result is judged as "Good." The result is judged as "No Good" if the pedal does not move down. With the engine running, depress the brake pedal. Stop the engine in this condition. The result is judged as "Good" when the pedal height does not change for approximately 30 seconds. The result is judged as "No Good" if the pedal moves up.
2. The brake booster is judged as normal when the results of all the above checks are "Good." When one or more of the above check results are "No Good," then the check valve, vacuum hose, or brake booster is suspected faulty.

INSPECTION USING SIMPLIFIED TESTER

Required Special Tool

1. MB992146: Booster test adapter installer

Scheme 15

1. Before starting this inspection, remove the brake booster check valve from the vehicle and check its operation (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).
2. After checking, install the check valve to the vacuum hose and connect it to the vacuum gauge. Install the booster test adapter (Special tool: MB992146) to the brake booster and connect it to the vacuum gauge. Connect the pressure gauge and pedal depression gauge as shown in the figure. Bleed the pressure gauge and then perform the following tests: Airtightness test with no load Start the engine, and stop it when the vacuum gauge indicator has reached approximately -67 kPa (-9.7 psi). The result is judged as "Good" when the drop of the vacuum approximately 15 seconds after the engine was stopped is within -3.3 kPa (-0.5 psi). Airtightness test with load Start the engine and depress the brake pedal with 200 N. Stop the engine when the vacuum gauge indicator reached approximately -67 kPa (-9.7 psi). The result is judged as "Good" when the drop of the vacuum approximately 15 seconds after the engine was stopped is within -3.3 kPa (-0.5 psi). When one or more of the above check results are judged as "No Good," the vacuum hose or brake booster is suspected faulty. Brake booster characteristics test Perform this test after the above (1) and (2) were performed. Non-servo effect test With the engine stopped, make sure that the vacuum gauge reading is 0 kPa (0 psi). Depress the brake pedal with 100 N (22.5 lb) and 300 N (67.4 lb), and measure the fluid pressure generated. Standard value: < Except RALLIART > BRAKE PEDAL DEPRESSION FORCE - EXCEPT RALLIART (NON-SERVO EFFECT TEST) Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 0 - 600 (0 - 87) 1,030 - 2,220 (149 - 322) < RALLIART > BRAKE PEDAL DEPRESSION FORCE - RALLIART (NON-SERVO EFFECT TEST) Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 0 - 520 (0 - 75) 890 - 1,910 (129 - 277) Servo effect test Start the engine. Depress the brake pedal with 100 N (22.5 lb) and 300 N (67.4 lb) when the vacuum gauge indicator reached approximately -67 kPa (-9.7 psi), and measure the fluid pressure generated. Standard value: < Except RALLIART > BRAKE PEDAL DEPRESSION FORCE - EXCEPT RALLIART (SERVO EFFECT TEST) Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 5,430 - 7,050 (787 - 1,022) 10,370 - 11,560 (1,504 - 1,676) < RALLIART > BRAKE PEDAL DEPRESSION FORCE - RALLIART (SERVO EFFECT TEST) Item Pedal depression force 100 N (22.5 lb) 300 N (67.4 lb) Generated fluid pressure kPa (psi) 4,430 - 5,850 (642 - 848) 8,950 - 9,970 (1,298 - 1,446)

Scheme 16

1. Remove the check valve (Refer to «REMOVAL AND INSTALLATION < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «REMOVAL AND INSTALLATION < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ). CAUTION: Replace the check valve when it is faulty.
2. Using a vacuum pump, check operation of the check valve. VACUUM PUMP CONNECTION CHART Vacuum pump connection Normal condition When connected to the booster side (1) Vacuum is generated and maintained. When connected to the engine side (2) No vacuum is generated.

BLEEDING

Brake fluid: DOT3 or DOT4

BLEEDING OF BRAKE PIPELINE

Perform the bleeding in the order shown in the figure.

Scheme 17

BRAKE FLUID LEVEL SWITCH CHECK

The brake fluid level switch is normal when the following conditions are met: When the brake fluid level is above "MIN," continuity is detected; and when the level is below "MIN," no continuity is detected.

Scheme 18

BRAKE PAD CHECK

Scheme 19

Scheme 20

Scheme 21

1. Visually check the thickness of brake pad from the inspection hole of the caliper body. Standard value: 10.0 mm (0.39 inch) Limit: 2.0 mm (0.08 inch)
2. If the brake pad thickness is less than the limit value, replace the brake pad (Refer to «BRAKE PAD REPLACEMENT < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__brake-pad-replacement-except-ralliart) or «BRAKE PAD REPLACEMENT < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).

BRAKE PAD REPLACEMENT < EXCEPT RALLIART >

Required Special Tool

1. MB990520: Disc Brake Piston Expander

< FRONT >

Scheme 22

Scheme 23

Scheme 24

1. Remove the parts indicated in the figure, swivel the caliper body upward and retain it with a wire or similar tool.
2. Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
3. Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
4. Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the guide pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb) NOTE: Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

Scheme 25

< REAR >

Scheme 26

Scheme 27

1. Remove the parts indicated in the figure, swivel the caliper body upward and retain it with a wire or similar tool.
2. Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
3. Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
4. Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the guide pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb) NOTE: Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.

Scheme 28

Required Special Tool

1. MB990520: Disc Brake Piston Expander

Scheme 29

Scheme 30

1. Remove the parts indicated in the figure, swivel the caliper body upward and retain it with a wire or similar tool.
2. Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
3. Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
4. Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the lock pin to the specified torque. Tightening torque: 74 ± 10 N.m (55 ± 7 ft-lb) NOTE: Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

Scheme 31

Scheme 32

1. Remove the parts indicated in the figure, swivel the caliper body upward and retain it with a wire or similar tool.
2. Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
3. Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
4. Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the guide pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb) NOTE: Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.

Scheme 33

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

DISC BRAKE INSPECTION TABLE

Scheme 34

1. Remove contaminants or corrosion from the brake disc surface.
2. Use a micrometer to measure the brake disc thickness at minimum eight points which are 10 mm (0.39 inch) inward from its circumference. Standard value: 26.0 mm (1.02 inches) < Front (Except RALLIART) > 24.0 mm (0.94 inch) < Front (RALLIART) > 10.0 mm (0.39 inch) < Rear > Limit: 24.4 mm (0.96 inch) < Front (Except RALLIART) > 22.4 mm (0.88 inch) < Front (RALLIART) > 8.4 mm (0.33 inch) < Rear >
3. If the brake disc thickness is worn beyond the limit value at more than one point, replace the brake disc and check its run-out.

Scheme 35

1. Remove contaminants or corrosion from the brake disc surface.
2. Use a micrometer to measure the brake disc thickness at minimum eight points which are 10 mm (0.39 inch) inward from its circumference. Then record the measurements.
3. If the brake disc thickness unevenness (the difference between the maximum and minimum values measured above) is 0.015 mm (0.0006 inch) or less, it is within the standard value.
4. If the brake disc thickness unevenness exceeds the standard value, grind it according to the procedure below while it is mounted on the vehicle. NOTE: If it is suspected that the brake disc thickness will become less than the limit value after the grinding, replace the brake disc and check its run-out. Check for wheel bearing looseness in the axial direction (Refer to «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution__wheel-bearing-end-play-check) < Front >, «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-fwd-except-lancer-evolution) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-awd-except-lancer-evolution) < Rear (AWD) >). CAUTION: Insert M12 plain washer and then install the adapter as shown in illustration before grinding. Failure to use the M12 plain washer will cause the brake disc to be deformed and ground incorrectly. To grind the brake disc, ensure that all the nuts (M12 X 1.5) are tightened evenly and in a diagonal sequence to the specified torque [100 N.m (74 ft-lb)]. Failure to use all the nuts (M12x1.5), excessive or uneven tightening torque will cause the brake disc to deform or judder. Correct the brake disc uneven thickness by grinding it while in place on the vehicle.

Scheme 36

1. Check for wheel bearing looseness in the axial direction (Refer to «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution__wheel-bearing-end-play-check) < Front >, «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-fwd-except-lancer-evolution) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/differentials-drive-axles/#rear-axle-awd-except-lancer-evolution) < Rear (AWD) >).
2. If the axial play is within the limit value, secure the brake disc by tightening the nut (M12x1.5) evenly to the specified torque [100 N.m (74 ft-lb)]. If the axial play still exceeds the limit value, replace the wheel bearing. Then secure the brake disc by tightening the nut (M12x1.5) evenly to the specified torque [100 N.m (74 ft-lb)].
3. Place a dial gauge ca. 5 mm (0.2 inch) inward from the circumference of the brake disc to measure its run-out. Limit: 0.06 mm (0.0024 inch) < Front > 0.08 mm (0.0032 inch) < Rear >
4. If the brake disc run-out exceeds the limit value, rephase the brake disc to the hub so that the minimum brake disc run-out is obtained. CAUTION: Insert M12 plain washer and then install the adapter as shown in illustration before grinding. Failure to use the M12 plain washer will cause the brake disc to be deformed and ground incorrectly. To grind the brake disc, ensure that all the nuts (M12 X 1.5) are tightened evenly and in a diagonal sequence to the specified torque [100 N.m (74 ft-lb)]. Failure to use all the nuts (M12x1.5), excessive or uneven tightening torque will cause the brake disc to deform or judder.
5. If the brake disc run-out exceeds the limit value after rephasing, grind the disc while in place on the vehicle so that the brake disc run-out is within the limit value. NOTE: If it is suspected that the brake disc thickness will be below the limit value, replace the brake disc. Then rephase the brake disc so that the minimum brake disc run-out is obtained, or grind the disc while in place on the vehicle so that its run-out is below the limit value.

Scheme 37

1. Remove the brake pad, shim and clip (Refer to «BRAKE PAD REPLACEMENT < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__brake-pad-replacement-except-ralliart) or «BRAKE PAD REPLACEMENT < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).
2. Using a spring scale, measure the hub sliding torque in the forward direction with the brake pad, shim and clip removed.
3. Install the brake pad, shim and clip (Refer to «BRAKE PAD REPLACEMENT < EXCEPT RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution__brake-pad-replacement-except-ralliart) or «BRAKE PAD REPLACEMENT < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).
4. Start the engine, and depress the brake pedal lightly two or three times. Then stop the engine. [Depressing force : approximately 50 - 100 N (11.2 - 22.5 pound)]
5. Turn the brake disc 10 times in the forward direction.
6. Using a spring scale, measure the hub sliding torque in the forward direction with the brake pad, shim and clip installed.
7. Obtain the disc brake drag force (difference between measured values of item 2 and item 6). Standard value: 68 N (15.3 pounds) or less < Front (Except RALLIART) > 85 N (19.1 pounds) or less < Front (RALLIART) > 68 N (15.3 pounds) or less < Rear >
8. If the brake drag force exceeds the standard value, disassemble the brake caliper assembly to check for fouling/rust on the piston sliding section and piston seal deterioration, and confirm whether the guide pin and lock pin slide properly (Refer to «DISASSEMBLY AND ASSEMBLY < 15-INCH FRONT DISC BRAKE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) , «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (EXCEPT RALLIART) >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) , «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (RALLIART) >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) , «DISASSEMBLY AND ASSEMBLY < 14-INCH REAR DISC BRAKE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) , «DISASSEMBLY AND ASSEMBLY < 16-INCH REAR DISC BRAKE (EXCEPT RALLIART) >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) or «DISASSEMBLY AND ASSEMBLY < RALLIART >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).

BRAKE LINING THICKNESS CHECK < VEHICLES WITH REAR DRUM BRAKE >

Scheme 38

1. Remove the brake drum.
2. Measure the thickness of the brake lining at the area with the most wear. Standard value: 4.0 (0.16 inch) 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/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) .

Scheme 39

1. Remove the brake drum.
2. Measure the inside diameter of the brake drum at two or more locations. Standard value: 203 mm (8.0 inches) Limit: 205 mm (8.1 inches)
3. Replace the brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM CONTACT CHECK < Vehicles with rear drum brake >

1. Remove the brake drum.
2. Remove the shoe and lining assembly (Refer to «REAR DRUM BRAKE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical-hydraulic/#basic-brake-system-except-lancer-evolution) ).
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 40

Scheme 41

Scheme 42

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 Multi-purpose grease or equivalent as shown in illustration.
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.

REMOVAL AND INSTALLATION

Scheme 43

< VEHICLES WITHOUT CRUISE CONTROL SYSTEM >

Check for continuity between the terminals of the switch.

STOPLIGHT SWITCH CONTINUITY CHECK - WITHOUT CRUISE CONTROL

Scheme 44

< VEHICLES WITH CRUISE CONTROL SYSTEM >

Check for continuity between the terminals of the switch.

STOPLIGHT SWITCH CONTINUITY CHECK - WITH CRUISE CONTROL

Scheme 45

Scheme 46

1. Place the brake pedal assembly on a level surface as shown in the figure, and set the distance from the center of the pin assembly mounting hole to the level surface to 97 mm (3.82 inches). Make sure that the dimension A in the figure (distance from the pedal pad center part to the level surface) is within the standard value. Standard value (A): 237 - 245 mm (9.3 - 9.6 inches) < M/T > 240 - 248 mm (9.4 - 9.8 inches) < CVT, TC-SST >
2. When dimension A is not within the standard value, replace the brake pedal assembly.

Scheme 47

Scheme 48

>> A << VACUUM HOSE INSTALLATION

Align the mark as shown in the figure to assemble the vacuum hose.

>> B << BLEEDING OF MASTER CYLINDER ASSEMBLY

When removed the master cylinder assembly, bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier (When no brake fluid is in the master cylinder).

Scheme 49

Scheme 50

1. Fill the brake fluid reservoir with the brake fluid.
2. Depress and hold the brake pedal.
3. Another operator closes the master cylinder outlets with his fingers.
4. In this condition, release the brake pedal.
5. Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with the brake fluid.

Scheme 51

Scheme 52

Align the mark as shown in the figure to assemble the vacuum hose.

Scheme 53

When removed the master cylinder assembly, bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier (When no brake fluid is in the master cylinder).

Scheme 54

1. Fill the brake fluid reservoir with the brake fluid.
2. Depress and hold the brake pedal.
3. Another operator closes the master cylinder outlets with his fingers.
4. In this condition, release the brake pedal.
5. Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with the brake fluid.

Scheme 55

Scheme 56

1. Pass the brake hose through the hole in the body-side bracket.
2. Install the brake hose to the brake caliper.
3. Install the brake hose at the two fixing points.
4. Twist the brake hose toward the lesser torsion between the brake hose and body-side bracket as shown in the figure, and fix it to the body-side bracket with a clip.

Scheme 57

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

Scheme 58

<< A >> PISTON BOOT/PISTON REMOVAL

Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.

<< B >> PISTON SEAL REMOVAL

Scheme 59

Scheme 60

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4

Scheme 61

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

Scheme 62

Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4

Scheme 63

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

Scheme 64

Remove the pistons and the piston boots by pumping in air from the brake hose connection. Be sure to use the handle of a plastic hammer and adjust the height of the two pistons so that the pistons protrude evenly.

Scheme 65

Scheme 66

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

BRAKE PAD WEAR INSPECTION

Measure the brake pad thickness at the most worn area. If the brake pad thickness is less than the limit value, replace the brake pad.

Standard value: 10.0 mm (0.39 inch)

Limit: 2.0 mm (0.08 inch)

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.

Scheme 71

Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4

Scheme 72

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.

Scheme 73

Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4

Scheme 74

Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.

Scheme 75

Scheme 76

Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4

Measure the brake pad thickness at the most worn area. If the brake pad thickness is less than the limit value, replace the brake pad.

Standard value: 10.0 mm (0.39 inch)

Limit: 2.0 mm (0.08 inch)

Scheme 77

Scheme 78

<< A >> PARKING BRAKE REAR CABLE REMOVAL

Withdraw the parking brake cable from the backing plate.

Note. Insert a 10 mm-wrench into the parking brake cable to facilitate the cable withdrawal.

Scheme 79

<< B >> RETAINER REMOVAL

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

Scheme 80

>> A << RETAINER INSTALLATION

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

Scheme 81

Scheme 82

Scheme 83

1. Use alcohol or brake fluid DOT3 or DOT4 to clean the wheel cylinder and the piston. CAUTION: In order to keep the piston cup from becoming twisted or slanted, slide the piston cup down special tool installer (MB990619) slowly and carefully, without stopping.
2. Apply brake fluid DOT3 or DOT4 to the piston cups and special tool installer (MB990619).
3. Set the piston cup on special tool with the lip of the cup facing up. Fit the cup onto special tool, and then slide it down the outside of special tool into the piston groove.

See also:
• PARKING BRAKE LINING AND DRUM
• PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT
• WHEEL BEARING END PLAY CHECK
• WHEEL BEARING END PLAY CHECK
• WHEEL BEARING END PLAY CHECK
• FRONT AXLE HUB ASSEMBLY
• WHEEL AND TIRE
• SHIFT LOCK MECHANISM CHECK
• SHIFT LOCK MECHANISM CHECK
• SYMPTOM CHART
• INSPECTION PROCEDURE 1: VEHICLE PULLS TO ONE SIDE WHEN BRAKES ARE APPLIED
• INSPECTION PROCEDURE 2: INSUFFICIENT BRAKING POWER
• BLEEDING
• BRAKE PAD CHECK
• BRAKE PEDAL CHECK AND ADJUSTMENT
• BRAKE PAD REPLACEMENT < EXCEPT RALLIART >