Mitsubishi Galant (2004+). Manual — part 506
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-11
INSPECTION PROCEDURE 8: 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 any 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
± 10 N⋅m (73 ± 7 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 100
± 10 N⋅m (74 ± 7 ft-lb) for the front
caliper. Tighten to 60
± 5 N⋅m (45 ± 3 ft-lb) for the rear
caliper. Then go to Step 5.
NO : Go to Step 4.
AC308605AB
<FRONT>
<REAR>
SPECIAL TOOLS
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BASIC BRAKE SYSTEM
35A-12
STEP 4. Check the wheel bearings for end play.
(1) Remove the brake discs.
(2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 5.
NO : Go to Step 5.
STEP 5. Recheck symptom.
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.
SPECIAL TOOLS
M1351000600360
AC102438 AC
<FRONT>
AC205869AC
<REAR>
TOOL
TOOL NUMBER AND
NAME
SUPERSESSION
APPLICATION
MB991568
Push rod adjusting socket
General service
tool
Adjustment of the brake booster
push rod protrusion amount
MB990964
Brake tool set
A: MB990520
Disc brake piston expander
MB990620-01 or
general service
tool
Pushing-in of the disc brake
piston
MB990964
A
B
ON-VEHICLE SERVICE
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BASIC BRAKE SYSTEM
35A-13
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900446
BRAKE PEDAL HEIGHT
1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value: 169.8
− 172.8 mm (6.69 − 6.80 inches)
[From the surface of dash panel to the face of pedal
pad]
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stoplight switch connector.
(2) Remove the brake booster (Refer to
).
NOTE: With the master cylinder and brake pipe con-
nected, remove the brake booster only.
(3) Adjust the brake pedal height by turning the clevis.
NOTE: When the clevis is turned 180 degrees, the pedal
height is changed by approximately 2.2 mm (0.09 in).
(4) Install the brake booster (Refer to
(5) Measure the brake pedal height, and ensure that the
measured value is within the specified value. If it is out of
the specified value, repeat Step (3) - (6).
(6) Screw in the stop light switch until its thread contacts the
stopper, and fix the stop light switch by turning it
approximately one quarter of a turn clockwise.
(7) Check that the clearance between the stop light switch
and the stopper is as shown.
CAUTION
Check that the stop light does not illuminate when the
brake pedal is not depressed.
(8) Connect the connector at the stop light switch.
4. Check the key interlock and shift lock mechanisms. (Refer to
GROUP 23A, On-vehicle Service
− Key Interlock and Shift
Lock Mechanism Check
).
5. Return the carpet, etc. to its original position.
AC210522
AC210523 AB
CLEVIS
AC206322 AB
0.5 - 1.5 mm
(0.02 - 0.06 in)
STOPPER
ON-VEHICLE SERVICE
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BASIC BRAKE SYSTEM
35A-14
BRAKE PEDAL FREE PLAY
1. Turn the ignition switch to the "LOCK" (OFF) position, and
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
• Brake pedal height
• Installation position of the stop light switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL AND
DASH PANEL
1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the dash panel.
Standard value: 110 mm (4.33 inches) or more [From
the surface of dash panel to the face of pedal pad]
3. If the clearance is outside the standard value, check for air
trapped in the brake line and check the thickness of the disc
brake pad. Andjust and replace defective parts as required.
4. Return the carpet etc. to its original position.
BRAKE BOOSTER OPERATING TEST
M1351001000372
1. For simple checking of the brake booster operation, carry
out the following tests:
(1) Run the engine for one or two minutes, and then stop it. If
the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective. Go to step 2.
AC206445
AB
AC206446
AB
AC000870
GOOD
NO GOOD
AB
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