Mitsubishi Lancer Evolution X. Manual — part 124
35A-1
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION . . . . . . . .
GENERAL SPECIFICATIONS . . . . . .
SERVICE SPECIFICATIONS. . . . . . .
LUBRICANTS . . . . . . . . . . . . . . . . . .
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION TO BASIC BRAKE SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . .
BASIC BRAKE SYSTEM DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . . .
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
SYMPTOM PROCEDURES . . . . . . . . . . . .
SPECIAL TOOLS. . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE. . . . . . . . . . .
BRAKE PEDAL CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
BRAKE BOOSTER OPERATION CHECK .
CHECK VALVE OPERATION CHECK . . . .
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUID LEVEL SWITCH CHECK . .
BRAKE PAD CHECK . . . . . . . . . . . . . . . . .
BRAKE PAD REPLACEMENT . . . . . . . . . .
DISK BRAKE ROTOR CHECK . . . . . . . . . .
BRAKE DRAG FORCE CHECK . . . . . . . . .
BRAKE PEDAL. . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
STOPLIGHT SWITCH CHECK . . . . . . . . . .
BRAKE PEDAL DISTORTION CHECK . . . .
MASTER CYLINDER ASSEMBLY AND
BRAKE BOOSTER ASSEMBLY . . . .
REMOVAL AND INSTALLATION . . . . . . . .
FRONT DISC BRAKE ASSEMBLY . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
REAR DISC BRAKE ASSEMBLY . . .
REMOVAL AND INSTALLATION . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY . . . . . . .
GENERAL INFORMATION
TSB Revision
BASIC BRAKE SYSTEM
35A-2
GENERAL INFORMATION
M1351000101119
The brake system has high reliability and durability,
and provides an exceptional braking performance.
FEATURES
.
IMPROVED BRAKING PERFORMANCE
• In addition to the 10-inch through bolt type single
brake booster, the small and long stroke-type
master cylinder is adopted to provide rigidity, to
reduce weight, and to secure the assist force.
• Brembo™ 18-inch 4-pot front ventilated disk
brakes and Brembo™ 17-inch 2-pot rear venti-
lated disk brakes are adopted to provide stable
braking force and improved braking feel.
• To the front, two-piece structure brake disk is
installed. <GSR: Option, MR: Standard>
.
IMPROVED STABILITY
• Front- and rear-wheel X-type brake line layout is
used.
• The brake pedal retreat suppression mechanism
that suppresses the retraction of brake pedal sur-
face upon a frontal collision is adopted.
• To the front brake and rear brake, the brake pads
with audible wear indicator are adopted which
warn the driver of the wear limit.
CONSTRUCTION DIAGRAM
AC708805AB
Brake booster
Master cylinder
Front disc brake
Reserve tank
Rear disc brake
Brake pedal
Hydraulic unit
GENERAL SPECIFICATIONS
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BASIC BRAKE SYSTEM
35A-3
GENERAL SPECIFICATIONS
M1351000200599
SERVICE SPECIFICATIONS
M1351000301403
Item
Specification
Master
cylinder
Type
Tandem type
I.D. mm (in)
23.81 (0.94)
Brake
booster
Type
Vacuum type, single
Effective dia. of power cylinder mm (in)
252 (10)
Boosting ratio
5.5 {Pedal depression force: 663 N (149 lb)}
Front brakes Type (Disk brake nomenclature)
Brembo™ 4-opposed-piston ventilated disk
(V8-Z4046)
Brake disk effective dia × thickness mm (in) 294 × 32 (11.6 × 1.3)
Cylinder I.D. mm (in) [Number of pistons]
40.0 (1.58) [2], 46.0 (1.81) [2]
Brake pad thickness mm (in)
9.85 (0.39)
Clearance adjustment
Automatic adjustment
Rear brakes Type (Disk brake nomenclature)
Brembo™ 2-opposed-piston ventilated disk
(V7-X40)
Brake disk effective dia × thickness mm (in) 278 × 22 (10.9 × 0.9)
Cylinder I.D. mm (in) [Number of pistons]
40.0 (1.58) [2]
Brake pad thickness mm (in)
9.0 (0.35)
Clearance adjustment
Automatic adjustment
Brake fluid
DOT3 or DOT4
Item
Standard value
Limit
Brake pedal height mm (in)
219.8 − 227.8 (8.7 − 9.0)
−
Dimension from the brake booster stud bolt end to the clevis
hole center mm (in)
74 (2.91)
−
Brake pedal free 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]
85 (3.35) or more
−
Front disk brake
Brake pad thickness mm (in)
9.85 (0.39)
2.0 (0.08)
Brake disk thickness mm (in)
32.0 (1.26)
30.0 (1.18)
Brake disk run-out mm (in)
−
0.06 (0.0024)
Brake drag force N (lb)
68 (15.3) or less
−
Rear disk brake
Brake pad thickness mm (in)
9.0 (0.35)
2.0 (0.08)
Brake disk thickness mm (in)
22.0 (0.87)
20.0 (0.79)
Brake disk run-out mm (in)
−
0.08 (0.0032)
Brake drag force N (lb)
68 (15.3) or less
−
Brake pedal distortion mm (in)
M/T
240 − 246 (9.4 − 9.7)
−
TC-SST
242 − 248 (9.5 − 9.8)
−
LUBRICANTS
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BASIC BRAKE SYSTEM
35A-4
LUBRICANTS
M1351000401002
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS
M1351009700405
Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disk brakes. Mal-
functions 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
M1351009800383
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
M1351009900410
Item
Specified lubricant
Quantity
Brake fluid
DOT3 or DOT4
Adequate
Brake pad assembly (between pad and
shim)
Repair kit grease (Color: Black), Molykote AS880N
or equivalent
Brake pad assembly (shoulder section)
Repair kit grease (Color: Copper), Molykote 7439 or
equivalent
Symptom
Inspection
procedure
Reference page
Vehicle pulls to one side when brakes are applied
1
Insufficient braking power
2
Increased pedal stroke (Reduced pedal-to-floor board clearance) 3
Brake drag
4
Scraping or grinding noise when brake are applied
5
Squealing, groaning or chattering noise when brake are applied
6
Squealing noise when brakes are not applied
7
Groaning, clicking or rattling noise when brakes are not applied
8
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