Mitsubishi Evolution X. Manual — part 821

BASIC BRAKE SYSTEM DIAGNOSIS

TSB Revision

BASIC BRAKE SYSTEM

35A-11

STEP 8. Adjust the brake pedal.
Refer to

P.35A-12

.

Q: Is the brake pedal adjusted correctly?

YES : Go to Step 9.
NO : Adjust the brake pedal. Then go to Step 9.

STEP 9. 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.

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 135

± 15 N⋅ m (100 ± 11 ft-lb) for the front

caliper. Tighten to 80

± 10 N⋅ m (59 ± 7 ft-lb) for the

rear caliper. Then go to Step 5.

NO : Go to Step 4.

STEP 4. Check the wheel bearings for end play.
Refer to GROUP 26

− On-vehicle Service, Wheel bearing end

play check

P.26-7

<Front> or GROUP 27

− On-vehicle Service,

Wheel bearing end play check

P.27-33

<Rear>.

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.

SPECIAL TOOLS

TSB Revision

BASIC BRAKE SYSTEM

35A-12

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

M1352000601526

Tool

Number

Name

Use

MB992146

MB992146

Booster test
adapter

Inspection using a simplified tester

MB990964

A

B

MB990964

A: MB990520

Brake tool set
A: Piston expander

Disk brake piston pushing back

ON-VEHICLE SERVICE

BRAKE PEDAL CHECK AND ADJUSTMENT

M1351003500737

CAUTION

Do not apply grease or lubricant to the switch and the
switch installation section to avoid malfunction of the
switch. In addition, do not use gloves which have grease
on them.

.

BRAKE PEDAL HEIGHT CHECK

1. Turn up the floor carpet under the brake pedal.
2. Remove the stoplight switch (Refer to

P.35A-25

).

AC505506AJ

B

A

Dash panel

Dash panel pad

Stoplight
switch

3. Use a needle or similar tool to measure the dimension A in

the figure (distance from the dash panel pad surface to the
dash panel).

4. Measure the dimension B in the figure (distance from the

pedal pad surface to the dash panel pad surface).

5. Make sure that the total of the dimensions A and B

measured in Steps 2 and 3 (brake pedal height) is within the
standard value.

Standard value (A+B): 219.8

− 227.8 mm (8.7 − 9.0 inch)

6. When the brake pedal height is not within the standard

value, inspect the brake pedal in the following procedure.

(1) Remove the brake pedal assembly (Refer to

P.35A-25

).

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-13

(2) Check the removed brake pedal assembly for distortion,

and replace it when deformed (Refer to

P.35A-26

).

(3) Install the brake pedal assembly (Refer to

P.35A-25

).

AC508163AB

C

Clevis

Stud bolt

(4) Measure the brake pedal height again, and make sure

that it is within the standard value (A+B).

When the measured value is not within the standard
value, measure the dimension C in the figure (distance
from the stud bolt end to the clevis hole center), and
make sure it is within the standard value (C).

Standard value (C): 74 mm (2.91 inch)

(5) When the measured value is not within the standard

value (C), replace the brake booster (Refer to

P.35A-27

).

AC309282 AG

0.5 to 1.5 mm
(0.02 to 0.06 in)

Pedal stopper

Pedal stopper

Stoplight switch

7. After checking the brake pedal height, install the stoplight

switch in the following procedure:

(1) Screw in the stoplight switch until its thread contacts the

pedal stopper, then turn the switch approximately one
eighth of a clockwise turn to fix it. While doing this, pull
and hold the brake pedal by hand.

(2) Check that the clearance between the stoplight switch

and the pedal stopper is as shown in the figure.

(3) Connect the stoplight switch connector.

NOTE: Make sure that the stoplight is not illuminated
when the brake pedal is not depressed.

8. Check the shift lock mechanism <TC-SST> (Refer to

GROUP 22C

− On-vehicle Service, Shift Lock Mechanism

Check

P.22C-332

).

9. Recover the floor carpet under the brake pedal.

.

ON-VEHICLE SERVICE

TSB Revision

BASIC BRAKE SYSTEM

35A-14

BRAKE PEDAL PLAY CHECK AND ADJUSTMENT

AC505506AF

D

1. With the engine stopped, depress the brake pedal 2 or 3

times to release the vacuum in the brake booster. Then,
press the brake pedal with your finger and check if the pedal
stroke until the pedal becomes heavy (play) is within the
standard value.

Standard value (B): 3

− 8 mm (0.12 − 0.31 inch)

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

check the brake pedal-to-clevis pin looseness, clevis
pin-to-booster operating rod looseness, brake pedal height,
and stoplight switch position, and adjust or replace as
necessary.

.

BRAKE PEDAL-TO-FLOOR PANEL CLEARANCE
CHECK AND ADJUSTMENT

1. Turn up the floor carpet or other similar material under the

brake pedal.

2. Using a needle or similar tools, measure the dimension E

shown in the figure (from the dash panel pad surface to the
dash panel).

AC706067AB

E

E + F

F

3. Start the engine, and depress the brake pedal with

approximately 500 N. Then, measure the dimension F
shown in the figure (from the center of pedal pad surface to
the dash panel pad surface).

4. Check that the sum of the dimensions E and F measured in

Steps 2 and 3 (clearance between the brake pedal and the
floor panel) is within the standard value.

Standard value (E+F): 85 mm (3.35 inch)

5. If the clearance between the brake pedal and the floor panel

is not within the standard value, check for the air intrusion in
brake line and the thickness of disk brake pad. Make
corrections or replace components as necessary.

6. Recover the floor carpet or other similar material under the

brake pedal.