Mitsubishi Galant. Manual — part 506

BASIC BRAKE SYSTEM DIAGNOSIS

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BASIC BRAKE SYSTEM

35A-15

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-17

or

P.35A-31

.

Q: Is the adjustment value come?

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

STEP 10. Recheck symptom.

Q: Is the symptom eliminated?

YES : Diagnosis is complete.
NO : Start over at step 1. If a new symptom surfaces, refer

to the symptom chart.

INSPECTION PROCEDURE 8: Groaning, clicking or rattling nose 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 88

−

108 N

⋅

m (66

−

81 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 90

−

110 N

⋅

m (66

−

81 ft-lb) for the front

caliper, or 55

−

65 N

⋅

m (41

−

48 ft-lb) for the rear

caliper. Then go to Step 5.

NO : Go to Step 4.

AC000863

SPECIAL TOOLS

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BASIC BRAKE SYSTEM

35A-16

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. Recheck symptom.

Q: Is the symptom eliminated?

YES : Diagnosis is complete.
NO : Start over at step 1. If a new symptom surfaces, refer

to the symptom chart.

SPECIA L TO O LS

M1351000600069

AC000862

WHEEL
BEARING

WHEEL
BEARING

<FRONT>

<REAR>

AB

TOOL

TOOL NUMBER AND
NAME

SUPERSESSION

APPLICATION

MB990964
Brake tool set
A: MB990520
Disc brake piston expander
B: MB990619
Installer

General service
tool

•

Pushing-in of the disc brake
piston

•

Installation of the drum brake
wheel cylinder piston cup

MB990998
Front hub remover and in-
staller

MB990998-01

Provisional holding of the wheel
bearing

MB990964

A

B

MB990998

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-17

O N -VEHIC LE SERVIC E

BRAKE PEDAL CHECK AND ADJUSTMENT

M1351000900060

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: 175

−−−−

178 mm (6.9

−−−−

7.0 inches) [From

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

(1) Disconnect the stoplight switch connector.
(2) Rotate the stoplight switch 1/4 turn counter clockwise to

loosen.

(3) Loosen the operating rod jam nut. Turn the serrations of

the operating rod with pliers to adjust the brake pedal
height to the standard value.

(4) Turn the stoplight switch until it contacts the stopper.

During this step, secure the pedal by moving it forward by
hand.

(5) Adjust the stoplight switch so that it has the specified

clearance as shown. Turn the stoplight switch 1/4 turn
clockwise to secure.

(6) Connect the connector of the stoplight switch.
(7) Check to be sure that the stoplight does not illuminated

with the brake pedal released

3. Return the carpet, etc. to its original position.

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 (0.12

−−−−

0.31 inch)

2. If the brake pedal play is not within the standard value,

check the following, and adjust or replace if necessary:

•

Excessive play between the brake pedal and the clevis pin,
or between the clevis pin and the brake booster operating
rod

AC000864 AB

STOPLIGHT
SWITCH

OPERATING
ROD

OPERATING
ROD JAM NUT

AC000865

PEDAL DOWN

PEDAL UP

JAM NUT

AB

AC000866AB

STOPPER

0.5

–

1.5 mm

(0.02

–

0.06 in)

AC000867

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-18

•

Brake pedal height

•

Installation position of the stoplight switch, etc.

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: 90 mm (3.5 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, thickness of the disc brake pad,
clearance between the lining and the drum and dragging in
the parking brake. And then adjust and replace defective
parts as required.

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

STOPLIGHT SWITCH CHECK

M1351008900086

1. Connect an ohmmeter between the stoplight switch

connector terminals.

2. There should be no continuity between the terminals when

the plunger is pushed in as shown. There should be
continuity when it is released.

BRAKE BOOSTER OPERATING TEST

M1351001000060

1. For simple checking of the brake booster operation, carry

out the following tests:

AC000868

TESTER CON-
NECTION

PLUNGER

SPECIFIED
CONDITION

1

−

2

IN

Open circuit

OUT

Less than 2

Ω

ACX00671AB

NO CONTINUITY CONTINUITY

4 mm

(0.16 in)