Mitsubishi Evolution X. Manual — part 819
SERVICE SPECIFICATIONS
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BASIC BRAKE SYSTEM
35A-3
SERVICE SPECIFICATIONS
M1351000301403
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
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 runout mm (in)
−
0.06 (0.0024)
Brake drag force N (lb)
68 (15.3) or less
−
Rear disk 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 runout 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)
−
Front brakes Type (Disk brake nomenclature)
Brembo
™ 4-opposed-piston ventilated disk
(V8-Z4046)
Disk effective dia
× thickness mm (in)
294
× 32 (11.6 × 1.3)
Cylinder I.D. mm (in)
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)
Disk effective dia
× thickness mm (in)
278
× 22 (10.9 × 0.9)
Cylinder I.D. mm (in)
40.0 (1.58)
× 2
Brake pad thickness mm (in)
9.0 (0.35)
Clearance adjustment
Automatic adjustment
Brake fluid
DOT3 or DOT4
Item
Specification
LUBRICANTS
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BASIC BRAKE SYSTEM
35A-4
LUBRICANTS
M1351000401002
Item
Specified lubricant
Quantity
Brake fluid
DOT3 or DOT4
Adequate
Brake pad assembly (between pad and
shim)
Repair kit grease, Molykote AS880N or equivalent
Brake pad assembly (shoulder section)
Repair kit grease, Molykote 7439 or equivalent
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
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
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-5
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad
contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES :
Replace the part and determine the
source/cause of foreign material. Then go to
Step 5.
NO :
Go to Step 2.
STEP 2. Check disk brake pistons for smooth
operation.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserves.
(2) Test each disk brake assembly one at a time.
a. Remove the lower caliper bolt, then remove
caliper from mount.
b. Have an assistant slowly depress the brake
pedal. Confirm piston(s) extend slowly and
smoothly with no jumpiness. Repeat for each
disk brake assembly.
Q: Do (does) the piston(s) move correctly?
YES :
Go to Step 3.
NO :
Disassemble and inspect the brake
assembly (Front: refer to
, Rear:
). Then go to Step 5.
STEP 3. Check brake disk(s) for runout.
Refer to
Q: Is runout outside of specifications?
YES :
Repair or replace the brake disk(s) as
necessary. Then go to Step 5.
NO :
Go to Step 4.
STEP 4. Check brake disks for correct thickness.
Refer to
Q: Is the thickness outside of specifications?
YES :
Repair or replace the brake disk(s) as
necessary. Then go to Step 5.
NO :
Perform the brake line bleeding. Then go to
Step 5.
STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO :
Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 2: Insufficient Braking Power
DIAGNOSIS
STEP 1. Check that the specified brake fluid is
used, its level is correct, and no contamination is
found.
Q: Is there a fault?
YES :
Refill or replace with the specified brake
fluid DOT 3 or DOT 4. Bleed the brakes if
necessary (Refer to
). Then go to
Step 6.
NO :
Go to Step 2.
STEP 2. Check for spongy (not firm) brakes.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete the booster
vacuum reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES :
Bleed the brakes to remove air in the fluid
). Then go to Step 6.
NO :
Go to Step 3.
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-6
STEP 3. Check the brake booster function.
Refer to
Q: Is there a fault?
YES :
Replace the brake booster. Then go to Step
6.
NO :
Go to Step 4.
STEP 4. Check for pinched or restricted brake
tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES :
Replace that complete section of brake tube
or brake hose. Then go to Step 6.
NO :
Go to Step 5.
STEP 5. Check for oil, water, etc., on the pad
contact surfaces of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES :
Replace the part and determine the
source/cause of foreign material. Recheck
symptom. Then go to Step 6.
NO :
The procedure is complete. Then go to Step
6.
STEP 6. 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 appropriate symptom
chart.
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)
DIAGNOSIS
STEP 1. Check for spongy (not firm) brakes.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES :
Bleed the brakes to remove air in the fluid
NO :
Go to Step 2.
STEP 2. Check the pad for wear.
Refer to
Q: Is the pad thickness outside of specifications?
YES :
Replace the part. Then go to Step 5.
NO :
Go to Step 3.
STEP 3. Check the vacuum hose and check valve
for damage.
Refer to
Q: Is there a damage?
YES :
Replace the part. Then go to Step 5.
NO :
Go to Step 4.
STEP 4. Check for brake fluid leaks.
Q: Is there a leak?
YES :
Check the connection for looseness,
corrosion, etc. Clean and repair as
necessary. If leaking in any tube or hose
section, replace the complete tube or hose.
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.
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