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Basic Brake System - Lancer Evolution: Diagnosis Mitsubishi Lancer X

Mechanical - Hydraulic 3 illustrations ~2212 words

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

SYMPTOMINSPECTION PROCEDURE
Vehicle pulls to one side when brakes are appliedINSPECTION PROCEDURE 1: VEHICLE PULLS TO ONE SIDE WHEN BRAKES ARE APPLIED
Insufficient braking powerINSPECTION PROCEDURE 2: INSUFFICIENT BRAKING POWER
Increased pedal stroke (Reduced pedal-to-floor board clearance)INSPECTION PROCEDURE 3: INCREASED PEDAL STROKE (REDUCED PEDAL-TO-FLOOR BOARD CLEARANCE)
Brake dragINSPECTION PROCEDURE 4: BRAKE DRAG
Scraping or grinding noise when brake are appliedINSPECTION PROCEDURE 5: SCRAPING OR GRINDING NOISE WHEN BRAKES ARE APPLIED
Squealing, groaning or chattering noise when brake are appliedINSPECTION PROCEDURE 6: SQUEALING, GROANING OR CHATTERING NOISE WHEN BRAKES ARE APPLIED
Squealing noise when brakes are not appliedINSPECTION PROCEDURE 7: SQUEALING NOISE WHEN BRAKES ARE NOT APPLIED
Groaning, clicking or rattling noise when brakes are not appliedINSPECTION PROCEDURE 8: GROANING, CLICKING OR RATTLING NOISE WHEN BRAKES ARE NOT APPLIED.

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 disk brake pistons for smooth operation. With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserves. Test each disk 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 disk 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»(ref-289400-S05547252242008063000000) , Rear: refer to «DISASSEMBLY AND ASSEMBLY»(ref-289400-S35584206642008063000000) ). Then go to Step 5 .
  3. STEP 3. Check brake disk(s) for runout. Refer to «DISK BRAKE ROTOR CHECK»(ref-289400-S19879477602008063000000) . Q: Is runout outside of specifications? YES : Repair or replace the brake disk(s) as necessary. Then go to Step 5 . NO : Go to Step 4.
  4. STEP 4. Check brake disks for correct thickness. Refer to «DISK BRAKE ROTOR CHECK»(ref-289400-S19879477602008063000000) . Q: Is the thickness outside of specifications? YES : Repair or replace the brake disk(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»(ref-289400-S05294232572008063000000) .
  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 «CHECK VALVE OPERATION CHECK»(ref-289400-S17028538792008063000000) ). 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 «CHECK VALVE OPERATION CHECK»(ref-289400-S17028538792008063000000) ). Then go to Step 6 . NO : Go to Step 3.
  3. STEP 3. Check the brake booster function. Refer to «BRAKE BOOSTER OPERATION CHECK»(ref-289400-S04520754062008063000000) . 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. Recheck symptom. Then go to Step 6. NO : The procedure is complete. Then 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»(ref-289400-S05294232572008063000000) .
  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 «CHECK VALVE OPERATION CHECK»(ref-289400-S17028538792008063000000) ). Then go to Step 5 . NO : Go to Step 2.
  2. STEP 2. Check the pad for wear. Refer to «BRAKE FLUID LEVEL SWITCH CHECK»(ref-289400-S36426571232008063000000) . Q: Is the pad thickness outside of specifications? YES : Replace the part. Then go to Step 5 . NO : Go to Step 3.
  3. STEP 3. Check the vacuum hose and check valve for damage. Refer to «CHECK VALVE OPERATION CHECK»(ref-289400-S17028538792008063000000) . Q: Is there a damage? YES : Replace the part. Then go to Step 5 . 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 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»(ref-289400-S05294232572008063000000) .

Scheme 10

Scheme 10: DIAGNOSIS
Scheme 10: DIAGNOSIS

Scheme 11

Scheme 11
Scheme 11
  1. STEP 1. Check the parking brake operating 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 shoe-to-anchor springs and adjusting wheel spring for breakage. Q: Are the shoe-to-anchor springs and adjusting wheel spring 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»(ref-289408-S35008392552008063000000) . 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»(ref-289408-S20486100572008063000000) . 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 disk 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»(ref-289400-S05294232572008063000000) .

Scheme 12

Scheme 12: DIAGNOSIS
Scheme 12: DIAGNOSIS
  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 cover and brake disk. 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 drums or disks for cracks. Q: Are there cracks? YES : Repair or replace the part. Then go to Step 6 . NO : Go to Step 5.
  5. STEP 5. Check for bent backing plate(s). Q: Is (Are) the backing plate(s) bent? YES : Repair or replace the part. Then go to Step 6. NO : Go to Step 6.
  6. STEP 6. Recheck symptom. Q: Is the symptom eliminated? YES : The procedure is complete. NO : Start over at Step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-289400-S05294232572008063000000) .
  1. STEP 1. Check the brake disk 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»(ref-289400-S22604874312008063000000) . 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»(ref-289400-S05294232572008063000000) .
  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 9 . 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 9 . 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 9 . NO : Go to Step 4.
  4. STEP 4. Check the brake disks for rust. Q: Are the brake disks 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 9 . NO : Go to Step 5.
  5. STEP 5. Check the brake pads for correct installation. Q: Are the pads installed incorrectly? YES : Repair the pads. Then go to Step 9 . NO : Go to Step 6.
  6. STEP 6. Check the calipers for correct installation. Q: Are the calipers installed incorrectly? YES : Repair the calipers. Then go to Step 9 . NO : Go to Step 7.
  7. STEP 7. Check the wheel bearings for end play. Refer to «WHEEL BEARING END PLAY CHECK»(ref-289401-S19854450872008063000000) < Front > or «WHEEL BEARING END PLAY CHECK»(ref-289399-S02395837622008063000000) < Rear >. Q: Does the measured end play exceed the limit? YES : Replace the faulty hub assembly. Then go to Step 9 . NO : Go to Step 8.
  8. STEP 8. Adjust the brake pedal. Refer to «BRAKE PEDAL CHECK AND ADJUSTMENT»(ref-289400-S22604874312008063000000) . Q: Is the brake pedal adjusted correctly? YES : Go to Step 9. NO : Adjust the brake pedal. Then go to Step 9.
  9. STEP 9. Recheck symptom. Q: Is the symptom eliminated? YES : The procedure is complete. NO : Start over at Step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-289400-S05294232572008063000000) .
  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. 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 135 ± 15 N.m (100 ± 11 ft-lb) for the front caliper. Tighten to 80 ± 10 N.m (59 ± 7 ft-lb) for the rear caliper. Then go to Step 5 . NO : Go to Step 4.
  4. STEP 4. Check the wheel bearings for end play. Refer to «WHEEL BEARING END PLAY CHECK»(ref-289401-S19854450872008063000000) < Front > or «WHEEL BEARING END PLAY CHECK»(ref-289399-S02395837622008063000000) < Rear >. Q: Does the measured end play exceed the limit? YES : Replace the faulty hub assembly. Then go to Step 5. NO : Go to Step 5.
  5. STEP 5. Recheck symptom. Q: Is the symptom eliminated? YES : The procedure is complete. NO : Start over at Step 1 . If a new symptom surfaces, refer to the «SYMPTOM CHART»(ref-289400-S05294232572008063000000) .

INSPECTION

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

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