Mitsubishi Montero (2004+). Manual — part 1002
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-7
STEP 2. Check disc brake pistons for smooth
operation.
(1) Depress the brake pedal repeatedly more than
40 times with the ignition switch at the "LOCK"
(OFF) position to release the pressure in the HBB
power supply system.
(2) Test each disc 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
disc brake assembly.
Q: Do (does) the piston(s) move correctly?
YES :
Go to Step 3.
NO :
Disassemble and inspect brake assembly
(Front: Refer to
/Rear: Refer to
STEP 3. Check brake disc(s) for run-out.
.
Q: Is run-out outside of specifications?
YES :
Repair or replace as necessary. Then go to
Step 5.
NO :
Go to Step 4.
STEP 4. Check brake discs for correct thickness.
.
Q: Is the thickness outside of specifications?
YES :
Repair or replace as necessary. Then go to
Step 5.
NO :
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 whether the brake fluid is low, is
the correct fluid (transmission fluid, engine oil,
etc.), or is contaminated (debris, sand, etc.).
Q: Is there 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) Depress the brake pedal repeatedly more than
40 times with the ignition switch at the "LOCK"
(OFF) position to release the pressure in the HBB
power supply system.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring stick (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
(Refer to
NO :
Go to Step 3.
STEP 3. Check the HBB function.
.
Q: Is the HBB malfunctioning?
YES :
) and
replace the faulty part as necessary. 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 pads on both left and right
wheels as a set and determine the
source/cause of foreign material. Then go to
Step 6.
NO :
Go to Step 6.
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-8
STEP 6. 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 3: Increased Pedal Stroke (Reduced Pedal-to-floor Board Clearance)
DIAGNOSIS
STEP 1. Check for spongy (not firm brakes).
(1) Depress the brake pedal repeatedly more than
40 times with the ignition switch at the "LOCK"
(OFF) position to release the pressure in the HBB
power supply system.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring stick (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
(Refer to
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 pads on both left and right
wheels as a set. Then go to Step 5.
NO :
Go to Step 3.
STEP 3. Check for brake fluid leaks.
Q: Are there brake fluid leaks?
YES :
Check the connection for looseness,
corrosion, etc. Clean and repair as
necessary. If there is a leak in any tube or
hose section, replace the complete tube or
hose. Then go to Step 5.
NO :
Go to Step 4.
STEP 4. Check the HBB's master cylinder
pistons.
(1) Remove the HBB (Refer to
(2) Check the power piston assembly and the master
cylinder piston assembly (Refer to
Q: Are the HBB master cylinder pistons
malfunctioning?
YES :
Replace the faulty part. Then go to Step 5.
NO :
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 4: Brake Drag
DIAGNOSIS
STEP 1. Check the parking brake lever return.
Q: Does the lever return abnormally?
YES :
When a foreign matter is caught in the
parking brake lever assembly, remove it.
When the foreign matter is not found,
replace the lever assembly (Refer to
GROUP 36, Parking Brake Lever
Then go to Step 8.
NO :
Go to Step 2.
STEP 2. Check the parking brake pull amount.
Refer to GROUP 36, On-vehicle Service
− Parking
Brake Lever Stroke Check and Adjustment
Q: Is the parking brake lever stroke out of
specification?
YES :
Adjust it. Then go to Step 8.
NO :
Go to Step 3.
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-9
STEP 3. Inspect the brake pedal return spring for
deterioration.
Q: Is there deterioration?
YES :
Replace the spring. Then go to Step 8.
NO :
Go to Step 4.
STEP 4. Inspect the brake shoe springs for
breakage.
Refer to GROUP 36, Parking Brake Drum
Q: Are the brake shoe springs broken?
YES :
Replace the springs. Then go to Step 8.
NO :
Go to Step 5.
STEP 5. Check the amount of grease at each
sliding section.
Refer to GROUP 36, Parking Brake Drum
Q: Is the grease amount insufficient?
YES :
Apply grease. Then go to Step 8.
NO :
Go to Step 6.
STEP 6. Check disc brake pistons for sticking.
Depress the brake pedal, then release. Confirm each
wheel spins freely. If any wheel is stuck, inspect that
brake assembly. Then go to Step 8.
Q: Are all wheels stuck?
YES :
Re-start from Step 1.
NO :
Go to Step 7.
STEP 7. Inspect the HBB's master cylinder
pistons.
(1) Remove the HBB (Refer to
(2) Inspect the power piston assembly and the
master cylinder piston assembly (Refer to
).
Q: Is there fault?
YES :
Replace the faulty part. Then go to Step 8.
NO :
Go to Step 8.
STEP 8. 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 5: Scraping or Grinding Noise when Brakes are Applied
DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes,
for metal-to-metal condition.
Q: Is the metal-to-metal contact evident?
YES :
Repair or replace the components. Then go
to Step 6.
NO :
Go to Step 2.
STEP 2. Check for interference between the
caliper and wheel.
Q: Is there interference?
YES :
Repair or replace the part. Then go to Step
NO :
Go to Step 3.
STEP 3. Check for interference between the dust
cover and brake disc.
Q: Is there interference?
YES :
Repair or replace the part. Then go to Step
NO :
Go to Step 4.
STEP 4. Check the brake discs for cracks.
Q: Are there cracks?
YES :
Repair or replace the part. Then go to Step
NO :
Go to Step 5.
STEP 5. Check for bent backing plate(s).
Q: Is (Are) the backing plate(s) bent?
YES :
Repair or replace the part. Then go to Step
NO :
Go to Step 6.
BASIC BRAKE SYSTEM DIAGNOSIS
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BASIC BRAKE SYSTEM
35A-10
STEP 6. 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 6: Squealing, Groaning or Chattering Noise when Brakes are Applied
DIAGNOSIS
STEP 1. Check the brake disc and pads for wear
or cutting.
Q: Is there wear or cutting?
YES :
Repair or replace the part. Then go to Step
NO :
Go to Step 2.
STEP 2. Check the calipers for rust.
Q: Is there rust?
YES :
Remove the rust. Then go to Step 4.
NO :
Go to Step 3.
STEP 3. Check the brake pedal.
Check the brake pedal height, brake pedal free play
and clearance between brake pedal and floorboard
(Refer to
Q: Is the brake pedal adjusted correctly?
YES :
Go to Step 4.
NO :
Adjust the brake pedal (Refer to
STEP 4. 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 7: Squealing Noise when Brakes are not Applied
DIAGNOSIS
STEP 1. Check the brake discs for rust.
Q: Are the brake discs rusted?
YES :
Remove the rust by using sand paper. If still
rusted, turn the rotors with an on-car brake
lathe. Then go to Step 6.
NO :
Go to Step 2.
STEP 2. Check the brake pads for correct
installation.
Q: Are the pads installed incorrectly?
YES :
Repair the pads. Then go to Step 6.
NO :
Go to Step 3.
STEP 3. Check the calipers for correct
installation.
Q: Are the calipers installed incorrectly?
YES :
Repair the calipers. Then go to Step 6.
NO :
Go to Step 4.
STEP 4. Check the wheel bearings for
deterioration or damage. Also check the grease
quality and quantity.
For front wheel, refer to GROUP 26, Hub and
Knuckle Assembly
. For rear wheel, refer to
GROUP 27, Rear Hub Assembly
.
Q: Are the wheel bearings damaged or out of grease?
YES :
Apply grease or replace the wheel bearings.
Then go to Step 6.
NO :
Go to Step 5.
STEP 5. Check the brake pedal.
Check the brake pedal height, brake pedal free play,
and clearance between brake pedal and floorboard
(Refer to
Q: Is the brake pedal adjusted correctly?
YES :
Go to Step 6.
NO :
Adjust the brake pedal (Refer to
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