2006-2008 Mitsubishi Outlander ZG Service & Repair Manual

GROUP 35A BASIC BRAKE SYSTEM CONTENTS GENERAL INFORMATION............35A-3 GENERAL SPECIFICATIONS.........35A-3 SERVICE SPECIFICATIONS.........35A-4 LUBRICANTS.....................35A-5 BASIC BRAKE SYSTEM DIAGNOSIS ...............................35A-5 INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS......................35A-5 BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY.......35A-5 SYMPTOM CHART..................35A-5 SYMPTOM PROCEDURES.............35A-6 INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied .................................35A-6 INSPECTION PROCEDURE 2: Insufficient Braking Power....................35A-7 INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance).................35A-7 INSPECTION PROCEDURE 4: Brake Drag .................................35A-8 INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied .................................35A-9 INSPECTION PROCEDURE 6: Squealing, Groaning or Chattering Noise when Brakes are Applied..............35A-10 INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied ................................35A-11 INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.................35A-12 SPECIAL TOOL..................35A-14 ON-VEHICLE SERVICE............35A-14 BRAKE PEDAL CHECK.............35A-14 BRAKE BOOSTER OPERATION CHECK ..............................35A-16 CHECK VALVE OPERATION CHECK ..............................35A-18 BLEEDING......................35A-18 BRAKE FLUID LEVEL SWITCH CHECK ..............................35A-19 DISC BRAKE PAD CHECK AND REPLACEMENT ..............................35A-20 BRAKE DISC THICKNESS CHECK....35A-21 BRAKE DISC RUNOUT INSPECTION AND CORRECTION....................35A-21 MASTER CYLINDER FUNCTION CHECK ..............................35A-22 BRAKE PEDAL...................35A-22 REMOVAL AND INSTALLATION......35A-22 BRAKE PEDAL INSPECTION........35A-24 CHECK THE STOPLIGHT SWITCH CONTINUITY. ................................35A-24 35A-1 Continued on next page

BRAKE PEDAL DISTORTION CHECK....35A-25 MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER.......................35A-25 REMOVAL AND INSTALLATION......35A-25 FRONT DISC BRAKE ASSEMBLY.....35A-28 REMOVAL AND INSTALLATION......35A-28 DISASSEMBLY AND ASSEMBLY......35A-30 FRONT DISC BRAKE ASSEMBLY INSPECTION ..............................35A-32 REAR DISC BRAKE ASSEMBLY......35A-33 REMOVAL AND INSTALLATION......35A-33 DISASSEMBLY AND ASSEMBLY......35A-35 REAR DISC BRAKE ASSEMBLY INSPECTION ..............................35A-37 35A-2

GENERAL INFORMATION M13501000001USA0000010001 Brake systems with higher reliability and durability have achieved distinguished braking performance. FEATURES IMPROVEMENT OF BRAKING PERFORMANCE ｠ In addition to the 10-inch single brake booster, the small and long stroke-type master cylinder is used to achieve the downsizing and secure the assist force. ｠ The installation of 16-inch ventilated disc brake on the front axle and 16-inch solid disc brake on the rear axle achieves the secure braking force and direct braking feeling. IMPROVEMENT IN SAFETY ｠ 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. ｠ Electronic control braking force distribution system (EBD) has been adopted to assure the maximum braking force independently of the passenger' position in the vehicle. ｠ X-type piping of brake lines have been adopted for the front and rear wheels. ｠ Audible wear indicator has been adopted to the front and rear brake pads to warn the driver of the wear limit. SERVICE QUALITY IMPROVEMENTS ｠ Diagnostic function has been adopted to ABS for easier inspection. ｠ Brake fluid reservoir, master cylinder, and brake booster have been integrated for downsizing and better serviceability. ZC6016900001 Brake booster Master cylinder Hydraulic unit Front disc brake Rear disc brake Reserve tank GENERAL SPECIFICATIONS M13501000002USA0000010001 Item Specifications Master cylinder Type Tandem type BASIC BRAKE SYSTEM 35A-3 GENERAL INFORMATION

Item Specifications I.D. mm (in) 20.6 (0.81) Brake booster Type Vacuum type, single Effective dia. of power cylinder mm (in) 255 (10.0) Boosting ratio 8.5 (Pedal pressure: 160N) Rear wheel hydraulic control method Electronic control braking force distribution system (EBD) Front brake Type Floating caliper 1 piston ventilated disc (V6-S57) Disc effective dia × thickness mm (in) 294 × 26 (11.6 × 1.02) Wheel cylinder I.D. mm (in) 57.1 (2.25) Pad thickness mm (in) 10.0 (0.39) Clearance adjustment Automatic adjustment Rear brake Type Floating caliper 1 piston solid disc (S6- S38) Disc effective dia × thickness mm (in) 302 × 10 (11.9 × 0.39) Wheel cylinder I.D. mm (in) 38.1 (1.50) Pad thickness mm (in) 10.0 (0.39) Clearance adjustment Automatic adjustment SERVICE SPECIFICATIONS M13501000003USA0000010000 Item Standard value Limit Brake pedal height mm (in) 221.8 - 227.8 (8.7 - 9.0) - Dimension from the brake booster stud bolt end to the clevis hole center mm (in) 75.8 - 80.2 (2.98 - 3.16) - Brake pedal play mm (in) 3 - 8 (0.12 - 0.31) - Pedal-to-floor clearance when brake pedal is depressed mm (in) [Pedal depression force: approx. 500 N] 80 (3.15) or more - Fluid pressure generated by brake booster non-servo effect test kPa (psi) Pedal depression force: 100 N 200 (29) or more - Pedal depression force: 300 N 1,800 (261) or more - Fluid pressure generated by brake booster servo effect test kPa (psi) Pedal depression force: 100 N 6,050 - 7,950 (877 - 1,153) - Pedal depression force: 300 N 10,720 (1,554) or more - Front disc brake Pad thickness mm (in) 10.0 (0.39) Minimum 2.0 (0.08) Brake disc thickness mm (in) 26.0 (1.02) Minimum 24.4 (0.96) Brake disc runout mm (in) - 0.06 (0.0024) 35A-4 BASIC BRAKE SYSTEM SERVICE SPECIFICATIONS

Item Standard value Limit Brake drag force N (lb) 68 (15.3) or less - Rear disc brake Pad thickness mm (in) 10.0 (0.39) Minimum 2.0 (0.08) Brake disc thickness mm (in) 10.0 (0.39) Minimum 8.4 (0.33) Brake disc runout mm (in) - 0.08 (0.0032) Brake drag force N (lb) 68 (15.3) or less - Front wheel bearing looseness mm (in) - 0.05 (0.0020) Rear wheel bearing looseness mm (in) - 0.05 (0.0020) Brake pedal distortion mm (in) 250 - 254 (9.8 - 10.0) - LUBRICANTS M13501000004USA0000010000 Item Specified lubricant Quantity Brake fluid DOT3 or DOT4 Adequate Master cylinder body, wheel cylinder body, piston cup, piston, piston seal Guide pin, lock pin, pin boot, bushing Repair kit grease (solid orange) Boot ring, piston boot Repair kit grease (translucent red) BASIC BRAKE SYSTEM DIAGNOSIS INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS M13501000097USA0000010000 Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster and disc 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 M13501000098USA0000010000 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 M13501000099USA0000010000 SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE Vehicle pulls to one side when brakes are applied 1 P.35A-6 Insufficient braking power 2 P.35A-7 Increased pedal stroke (Reduced pedal-to-floor board clearance) 3 P.35A-7 Brake drag 4 P.35A-8 Scraping or grinding noise when brake are applied 5 P.35A-9 BASIC BRAKE SYSTEM 35A-5 LUBRICANTS

2006-2008 Mitsubishi Outlander ZG Service & Repair Manual

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