Basic Brake System - Lancer: Other Mitsubishi Lancer X

IMPROVEMENT OF BRAKING PERFORMANCE

1. A 10-inch single brake booster with the variable boost ratio mechanism has been used to assure maximum braking force with less pedal pressure in case of emergency.
2. In addition to the 10-inch single brake booster, a small and long stroke-type master cylinder has been adopted to achieve downsizing and secure assist force.
3. 15-inch or 16-inch ventilated disc brakes have been adopted for the front.
4. 8-inch leading trailing-type drum brake, 14-inch or 16-inch solid disc brake has been adopted for the rear.

IMPROVEMENT IN SAFETY

1. The 4-wheel anti-lock brake system (4ABS) has been installed to prevent slippage resulting from the wheel lock and assure stable vehicle posture and driveability.
2. A rear wheel early lock-prevention proportioning valve has been used. < Vehicles without ABS>
3. Electronic control braking force distribution system (EBD) has been adopted to assure the maximum braking force independently of the passenger's position in the vehicle.
4. X-type piping of brake lines have been adopted for the front and rear wheels.
5. Audible wear indicators are used on the front and rear brake pads to warn the driver of wear limit.

SERVICE QUALITY IMPROVEMENTS

1. Diagnostic function has been adopted to ABS for easier inspection.
2. Brake fluid reservoir, master cylinder, and brake booster have been integrated for downsizing and better serviceability.

< Vehicles without ABS>

Scheme 103

Scheme 104

LUBRICANTS

LUBRICANTS SPECIFICATIONS

BLEEDING

Brake fluid: DOT3 or DOT4

BLEEDING OF MASTER CYLINDER

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).

1. Fill the brake fluid reservoir with 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 brake fluid.

BLEEDING OF BRAKE PIPELINE

1. Perform the bleeding in the order shown in the figure.

Scheme 105

DISC BRAKE ROTOR CHECK

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

BRAKE DISC INSPECTION ITEMS AND REMARKS REFERENCE

Scheme 106

Scheme 107

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) Rear 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 ("MAD, DL-8700PF" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disc.

Scheme 108

Scheme 109

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 (0.2 inch) from the outer circumference of the brake disc, and measure the run-out of the disc. 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, 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. Set a dial gauge as shown in the figure, and measure looseness of the hub in the axial direction. Limit: 0.05 mm (0.002 inch) When the looseness exceeds the limit value, replace the front or rear hub assembly. When the looseness is within the limit value, install the brake disc after changing the phase between the hub and the brake disc, then check the runout of the brake disc again. 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 < Vehicles with rear drum brake>

Scheme 110

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) 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 < VEHICLES WITH REAR DRUM BRAKE>»(ref-291270-S15857758692008072500000) .

Scheme 111

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 < VEHICLES WITH REAR DRUM BRAKE>»(ref-291270-S15857758692008072500000) ).
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 112

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 Chuo Yuka AKB 100 or equivalent 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.

MASTER CYLINDER FUNCTION CHECK

1. Remove the reservoir cap.
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, 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, replace the master cylinder.

CHECK THE STOP LAMP SWITCH CONTINUITY.

1. Connect a circuit tester (ohmsrange) to the stop lamp switch connector.
2. When no continuity is detected with the plunger pressed from the edge of the outer case by the dimension shown in the figure and when continuity is detected with the plunger released, the stop lamp switch is in good condition.

Scheme 113

Scheme 114

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 inch). 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 inch) < M/T> 240 - 248 mm (9.4 - 9.8 inch) < CVT>
2. When dimension A is not within the standard value, replace the brake pedal assembly.