Basic Brake System: Removal & Installation Mitsubishi Outlander II

<< A BRAKE PEDAL ASSEMBLY REMOVAL

From the engine compartment side, remove the brake pedal assembly while pulling the brake booster.

Scheme 12

1. Install the snap pin as shown in the figure.

Scheme 13

1. Connect a circuit tester (ohmsrange) to the stop light 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 stoplight switch is in good condition.

Scheme 14

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 surface to the level surface) is within the standard value. Standard value (A): 250 - 254 mm (9.8 - 10.0 inch)
2. When dimension A is not within the standard value, replace the brake pedal assembly.

REMOVAL AND INSTALLATION

Scheme 15

A << SNAP PIN INSTALLATION

1. Install the snap pin as shown in the figure.

Scheme 16

Scheme 17

1. Install the check valve to the brake booster as shown in the figure.
2. As shown in the figure, insert the brake booster-side vacuum hose into the brake booster check valve with its yellow mark facing the vehicle front, and fix with a hose clip. Insert the inlet manifold-side vacuum hose into the vacuum pipe with the white marks aligned, and fix with a hose clip.

Scheme 18

Scheme 19

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.

B << BRAKE CALIPER ASSEMBLY INSTALLATION

Measure the brake drag force in the following procedure

Scheme 20

Scheme 21

Scheme 22

1. Using a spring scale, measure the hub sliding torque in the forward direction. CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
2. Clean the piston, and press the piston into the cylinder using the piston expander (Special tool: MB990520).
3. Assemble the pad clip and pad to the caliper support, and tighten the guide pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
4. Start the engine, and depress the brake pedal forcibly two or three times. Then, stop the engine.
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.
7. Obtain the disc brake drag force (difference between measured values of item 1 and item 6). Standard value: 68 N (15.3 pounds) or less
8. If the brake drag force exceeds the standard value, disassemble the piston to check for fouling/rust on the piston sliding section and piston/seal deterioration, and confirm whether the slide pin slides properly.

Scheme 23

Scheme 24

<< 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.

Scheme 25

<< B PISTON SEAL REMOVAL

Scheme 26

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

A << REAR BRAKE CALIPER ASSEMBLY INSTALLATION

Measure the brake drag force in the following procedure

Scheme 27

Scheme 28

1. Using a spring scale, measure the hub sliding torque in the forward direction. CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
2. Clean the piston, and press the piston into the cylinder using the piston expander (Special tool: MB990520).
3. Install the caliper support to the backing plate assembly, and assemble the pad clip and pad to the caliper support.
4. Lower the caliper assembly with care not to catch the piston boot, and tighten the lock pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
5. Start the engine, and depress the brake pedal forcibly two or three times. Then, stop the engine.
6. Turn the brake disc 10 times in the forward direction.
7. Using a spring scale, measure the hub sliding torque in the forward direction.
8. Obtain the disc brake drag force (difference between measured values of item 1 and item 7). Standard value: 68 N (15.3 pounds) or less
9. If the brake drag force exceeds the standard value, disassemble the piston to check for fouling/rust on the piston sliding section and piston/seal deterioration, and confirm whether the slide pin slides properly.

Scheme 29

Scheme 30

<< A PISTON/PISTON BOOT 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.

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