Mitsubishi Montero Sport (2004+). Manual — part 772

BASIC BRAKE SYSTEM DIAGNOSIS

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BASIC BRAKE SYSTEM

35A-13

STEP 8. Check whether the brake booster, master cylinder
or wheel cylinder return is insufficient.
Q: Is the brake booster, master cylinder or wheel cylinder

return insufficient?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 9.

STEP 9. Adjust the brake pedal or brake booster pushrod.

Refer to

P.35A-15

or

P.35A-28

.

Q: Is the adjustment value come?

YES : Adjust. Then go to Step 10.
NO : Go to Step 10.

STEP 10. Retest the system.
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

P.35A-3

.

INSPECTION PROCEDURE 9: Groaning, Clicking or Rattling Noise when Brakes are not Applied.

.

DIAGNOSIS

STEP 1. Check whether foreign material has entered the
wheel covers.
Q: Is there foreign material?

YES : Remove it. Then go to Step 5.
NO : Go to Step 2.

STEP 2. Check for looseness of the wheel nuts.
Q: Are the wheel nuts loose?

YES : Tighten to 98

− 120 N⋅m (72 − 87 ft-lb). Then go to

Step 5.

NO : Go to Step 3.

STEP 3. Check for looseness of the caliper installation
bolt.

Q: Is the caliper installation bolt loose?

YES : Tighten to 88 N

⋅m (65 ft-lb). Then go to Step 5.

NO : Go to Step 4.

AC000863

AB

SPECIAL TOOLS

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BASIC BRAKE SYSTEM

35A-14

STEP 4. Check the wheel bearings for wear, damage or
dryness.

Q: Is there fault?

YES : Apply grease or replace the part. Then go to Step 5.
NO : Go to Step 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 surfaces, refer

to the symptom chart

P.35A-3

.

SPECIAL TOOLS

M1351000600393

AC005073 AB

<FRONT>

<REAR>

WHEEL BEARING

WHEEL
BEARING

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990964
Brake tool set
A: MB990520
Disc brake piston expander
B: MB990623
Installer

General service
tool

• Pushing-in of the disc brake

piston

• Installation of the drum brake

wheel cylinder piston cup

MB991714
Pushrod adjust gauge

−

Clearance adjustment between
brake booster pushrod and
master cylinder primary piston

MB990964

A

B

B

MB991714

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-15

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND ADJUSTMENT

M1351000900468

.

BRAKE PEDAL HEIGHT
1. Turn up the carpet etc. under the brake pedal.
2. Measure the brake pedal height as illustrated. If it is not

within the standard value, adjust as follows.

Standard value: 176

− 181 mm (6.9 − 7.1 inches) [From

the surface of melting sheet (floorboard) to the face of
pedal pad]

(1) Disconnect the stoplight switch connector, loosen the jam

nut and move the stoplight switch to a position where it
does not contact the brake pedal arm.

(2) Adjust the brake pedal height by turning the operating rod

with pliers (with the operating rod jam nut loosened).

(3) Screw in the stoplight switch until it contacts the brake

pedal stopper (just before brake pedal begins to move).
Return the stoplight switch half to one turn and secure
with the jam nut.

(4) Connect the connector of the stoplight switch.
(5) Check to be sure that the stoplight is not illuminated with

the brake pedal released.

3. Turn back the carpet etc. to original position.

.

AC005033 AB

OPERAT-
ING ROD

OPERATING
ROD JAM
NUT

STOPLIGHT
SWITCH

STOPLIGHT
SWITCH
JAM NUT

ACX01815AB

JAM NUT

PEDAL UP

PEDAL
DOWN

AC005034 AB

0.5 - 1.0 mm
(0.02 - 0.04 in)

OUTER CASE

JAM NUT

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-16

BRAKE PEDAL FREE PLAY
1. Turn the ignition switch to the "LOCK" (OFF) position,

depress the brake pedal two or three times. After eliminating
the vacuum in the brake booster, press the pedal down by
hand, and confirm that the amount of movement before
resistance is met (free play) is within the standard value
range.

Standard value: 3

− 8 mm (0.1 − 0.3 inch)

2. If the free play exceeds the standard value, it is probably

due to excessive play between the clevis pin and brake
pedal arm.

3. Check for excessive clearance and replace faulty parts as

required. (Refer to

P.35A-27

.)

.

CLEARANCE BETWEEN BRAKE PEDAL AND
FLOORBOARD
1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with

approximately 490 N (110 pound) of force, and measure the
clearance between the brake pedal and the floorboard.

Standard value: 95 mm (3.7 inches) or more [From the
surface of melting sheet (floorboard) to the face of
pedal pad]

3. If the clearance is outside the standard value, check for air

trapped in the brake line, clearance between the lining, and
the drum and dragging in the parking brake. Adjust and
replace defective parts as required.

4. Return the carpet etc. to its original position.

STOPLIGHT SWITCH CHECK

M1351008900257

Connect an ohmmeter to the stoplight switch, and Check for
continuity by pushing in and releasing the stoplight switch. The
stoplight switch is in good condition if there is no continuity
when the plunger is pushed in to a depth of within 4 mm (0.2
inch) from the outer case edge surface, and if there is continu-
ity when it is released.
Check for continuity between the terminals "a" and "b" of the
stoplight switch.

AC005035 AB

AC005036AB

AC004299 AC

NO CONTINUITY

CONTINUITY

PLUNGER

a

b