Mitsubishi Galant 9G. Manual — part 405

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

P.35A-26

).

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

P.35A-26

).

(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

P.23A-378

).

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

ON-VEHICLE SERVICE

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BASIC BRAKE SYSTEM

35A-15

(2) With the engine stopped, step on the brake pedal several

times. Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.

(3) With the engine running, step on the brake pedal and

then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster
is in good condition, if the pedal rises, the booster is
defective.

2. If the above three tests are okay, the booster is OK. If one of

the above three tests is not okay, the check valve, vacuum
hose, or booster is defective. Check the check valve (Refer
to

P.35A-15

), vacuum hose for leaks, high volume engine

vacuum applied to booster. Repair or replace as necessary.
If these are OK, replace booster and repeat this test starting
at Step 1.

CHECK VALVE OPERATION CHECK

M1351009000376

CAUTION

The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to

P.35A-26

).

CAUTION

If the check valve is defective, replace it as an assembly
together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum

pump.

AC000871 AB

WHEN ENGINE
IS STOPPED

WHEN ENGINE
IS STARTED

AC000872

GOOD

NO GOOD

AB

VACUUM PUMP
CONNECTION

CRITERIA

Connection at the brake
booster side (A)

A negative pressure
(vacuum) is created and
held.

Connection at the intake
manifold side (B)

A negative pressure
(vacuum) is not created.

AC000873 AB

A

B

VALVE

SPRING

INTAKE
MANIFOLD
SIDE
(DOES NOT
HOLD)

BOOST-
ER SIDE
(HOLDS)