1989 MITSUBISHI GALANT Service Repair Manual

35-8SERVICE BRAKES - SDecifications
SERVICE SPECIFICATIONS [Up to 1992 models]
FWD
Items
AWDSOHCDOHC
Standard value
Brake pedal height mm (in.) 176-181 (6.9-7.1)
176-181
(6.9-7.1)176-181 (6.9-7.1)
Brake pedal free playmm (in.) 3-8 (l-.3)3-8 (.I -.3)3-8 (.I -.3)
Brake pedal to floorboard
clearance mm (in.) 80 (3.1) or more 80 (3.1) or more80
(3.1) or more
Proportioning valve
pressure MPa (psi)
Split point 3.95-4.45
(561-633) 3.45-3.95 (491-561)4.95-5.45 (704-775)
Output pressure5.55-6.05 (789-861) 4.65-5.15 (661-732) 6.55-7.05 (931-[input pressure]
(8.2 (1,163)1[7.7 (1,095)11,003) 19.2 (1,309)1
Booster push rod to
master cylinder piston
clearance mm (in.)
9 inch brake booster
0.8-l .O (.031-,039)0.8-I .O (.031-.039)-
7 +8 inch brake booster0.5-0.7 (.020-.028)0.5-0.7 (.020-.028)
8+ 9 inch brake booster--0.6-0.8 (.024-.031)
Disc brake drag force
(tangential force of wheel
mounting bolts)
N (Ibs.) 70 (15.4) or less 70 (15.4) or less70 (15.4) or less
Speed sensor’s internal
resistance
kQ -0.8-I .2*0.8-1.2”
Clearance between the speed
pole piece and the toothed rotor mm (in.)
-0.3-0.9 (.012-,035)”0.3-0.9 (.012-.035)*
.imit
Left/right proportioning valve
output pressure difference MPa (psi) 0.4 (57)
0.4 (57)0.4 (57)
Front disc runout
mm (in.)
0.08
(.0031), 0.07 (.0028)” 0.08 (0031). 0.07 (0028)”
0.08 (0031). 0.07 (.0028)”
Pad thickness mm (in.) 2.0 (.08)2.0 (.08)2.0 (.08)
Front disc thickness
mm (in.) 22.4 (.882)22.4 (.882)22.4 (.882)
Rear disc thicknessmm (in.) -8.4 (.331)8.4 (.331)
Rear disc runout
mm (in.) -0.08 (.0031)0.08 (.0031)
Rear drum lining thickness
mm (in.) 1.0 (.04)-
Rear drum inside diameter
mm (in.) 205 (8.1)-
NOTEl :Vehicles
with ABSl *: 1992 models
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SERVICE BRAKES - Specifications35-9
SERVICE SPECIFICATIONS [1993 models]
ItemsSOHCDOHC
Standard value
Brake pedal height mm (in.) 176-181 (6.9-7.1)
176-181 (6.9-7.1)
Brake pedal free play mm (in.)3-8 (.I
-.3)3-8 (.I -.3)
Brake pedal to floorboard clearance
mm (in.)80 (3.1) or more 80 (3.1) or more
Proportioning valve pressure MPa
(psi)
Split point 3.95-4.45
(561-633)3.45-3.95 (491-561)
Output pressure5.55-6.05 (789-861)4.65-5.15 (661-732)
[input pressure][8.2 (1 ,I 63)][7.7 (1,095)]
Booster push rod to master cylinder piston clearancemm (in.)
9 inch brake booster0.8-l .O (.031-,039)0.8- 1 .O (.031-.039)
7
+ 8 inch brake booster0.5-0.7 (.020-.028)
Disc brake drag force (tangential force of wheel mounting bolts)
N (Ibs.)70 (15.4) or less 70 (15.4) or less
[Disc brake dragging torque] Nm (ftlbs.)[4 (3) or less] [4 (3) or less]
Speed sensor’s internal resistance
k& -0.8- 1.2*
Clearance between the speed pole piece and the toothed rotor mm (in.) -0.3-0.9 (.012-.035)*
-imit
Left/right proportioning valve output pressure difference
MPa
(psi) 0.4 (57)0.4 (57)
Front disc runout
mm (in.) 0.07 (.0028)0.07 (0028)
Pad thickness mm (in.) 2.0
(.08)2.0 (.08)
Front disc thickness
mm (in.) 22.4 (.882)22.4 (882)
Rear disc thickness
mm(in.) -8.4 (.331)
Rear disc runout
mm (in.) -0.08 (.003 1)
Rear drum lining thicknessmm (in.)1 .O (04)
Rear drum inside diameter
mm (in.) 205 (8.1)
NOTE* : Vehicles with A.B.S.
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35-10SERVICE BRAKES - Specifications
TORQUE SPECIFICATIONS
Items
Pedal support bracket installation bolts
Pedal support bracket installation nut
Pedal rod to pedal support bracket
Pedal rod to clutch pedal bracket
Stop light switch mounting nut
Clutch master cylinder installation nuts
Clutch pedal installation nut
Lever assembly (A) installation nut
-ever assembly (B) installation nut Vlaster
cylinder to brake booster qeservoir
installation bolt
‘iston stopper bolt Vipple installation screw
3rake booster installation nuts
q itting
Ilared brake line nuts
3rake hose bracket installation bolts
+ont disc brake assembly installation bolts
-ock
pin (front) 3uide
pin (front)
31eeder screw
3acking plate to axle beam
JVheel bearing nut (vehicles with rear drum brakes)
JVheel cylinder installation bolts Yheel
bearing nut (vehicles with rear disc brakes)
just shield to axle beam
Iear disc brake assembly installation bolts
srake hose to caliper body (rear)
.ock pin (rear)
&ride pin (rear)
Irive shaft to companion flange
\xle shaft installation nut
brake lever installation nut
iydraulic unit mounting bolts
Ieserve tank bracket (upper)
bracket A installation bolts ;peed sensor bracket installation bolt
totor to front hub
‘otor to rear hub
G-sensor installation bolt and nut
NOTE*I: >
~2: *3: *4:
Nmft.lbs.
8-126-
9
IO-157-11
17-26 12-19
17-26 12-19
IO-157-l 1
IO-157-11
,25-35”’ [20-251*218-25”’ [14-181*2
25-35*’ [20-251*218-25*’
[14-181*2
20-2514-18
8-1
2
6-9
1.5-3.0l-2
1.5-3.0l-2
1.5-3.0l-2
11-178-1
2
15-18 11-13
13-17 9-12
17-26 12-19
80-10058-72
22-32*3 [64-86]*41 6-23*3 [46-621*4
22-32*3 [64-86]*41 6-23*3 [46-62]*4
7-
9
5-7
50-6036-4
3
20~0~1014-047
8-1

2
6-9 ZOO-260
144-188
9-14
7-10
50-6036-4
3
25-35 18-25
22-32 16-23
22-32 16-23
55-65
40-47
160-220116-159
50-6036-4
3
40-5529-40
9-1

4
7-10
17-26
12-19
9-1
4
7-10
17-26
12-19
9-1
4
7-10
9-1

4
7-10
9-1

4
7-10
9-1

4
7-10
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SERVICE BRAKES - Specifications/Special Tools35-l 1
LUBRICANTS
Items
Brake fluid
Brake piston seal
Brake piston boot inner surfaces
Brake lock pin boot inner surfaces
Guide pin boot inner surfaces
Lock pin sleeve
Guide pin and caliper support contact surface
Lock pin and caliper support contact surface
Rear drum brake wheel cylinder ends
Spindle lever, lever boot, connecting link, O-ring and
auto adjuster spindle Specified lubricant
Conforming to
DOT3 or DOT4
Repair kit grease (orange)
Pad and outer shim contact surface and inner shim
and inner shim contact surface and inner shim and pad
Rear drum brake backing plate contact surfaces
Rear drum brake anchor plates and piston ends Brake grease SAE J310,
NLGI No. 1
SEALANT AND ADHESIVES
,
Items
Specified sealant
Thread part fitting 3M
ATD Part No.8663
or equivalent
Wheel cylinder mounting surfaces 3M
ATD Part No.8513
or equivalent
SPECIAL TOOLS
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SERVICE BRAKES - Special Tools/Troubleshooting
SERVICE TOOL
(For the number, refer to GROUP OO-Precautions before service.)
TROUBLESHOOTING
Symptom
Vehicle pulls to one side
when brakes are applied Probable cause
Grease or oil on pad or lining surface
Inadequate contact of pad or lining
Auto adjuster malfunction
Drum eccentricity or uneven wear Remedy
Replace
Correct
Adjust Repair or replace as necessary
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SERVICE BRAKES - Troubleshooting35-13
SymptomInsufficient braking
power Probable cause
Low or deteriorated brake fluid
Air in brake system Overheated brake rotor due to dragging of pad or
lining Remedy
Refill or change
Bleed air
Correct
Inadequate contact of pad or lining
Brake booster malfunction
Clogged brake line
Grease or oil on pad or lining surface
Replace
Proportioning valve malfunction
Auto adjuster malfunction Adjust
Increased pedal stroke Air in brake system Bleed air’
(Reduced pedal to floor-
board clearance) Worn lining or pad
Replace
Broken vacuum hose
Faulty master cylinder
Brake fluid leaks Correct
Auto adjuster malfunction Adjust
Excessive push rod to master cylinder clearance
Brake dragIncomplete release of parking brake Correct
Clogged master cylinder return port Incorrect parking brake adjustment Adjust
Improper push rod to master cylinder clearance
Faulty master cylinder piston return spring
Replace
Worn brake pedal return spring Broken rear drum brake shoe return spring
Lack of lubrication in sliding parts Lubricate
Insufficient parking Worn brake lining or pad
Replace
Drake function
Grease or oil on lining or pad surface
Parking brake cable sticking
Stuck wheel cylinder or caliper piston
Excessive parking brake lever stroke Adjust the parking brake lever
stroke or check the parking brake
cable routing
Auto adjuster malfunction Adjust
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-..

35-14SERVICE BRAKES - Troubleshooting
Symptom
Scraping or grinding
noise when brakes are
applied Probable cause
Worn brake lining or pad
Caliper to wheel interference
Dust cover to disc interference Remedy
Replace
Correct or replace
Bent brake backing plate
Cracked drums or brake disc
Squealing, groaning or
chattering noise when
brakes are applied Disc brakes-missing or damaged brake pad anti-
squeak shim Replace
Brake drums and linings, discs and pads worn or
scored Correct or replace
Improper lining parts
Disc brake-burred or rusted calipers
Dirty, greased, contaminated or glazed linings
Drum brakes-weak, damaged or incorrect shoe
hold-down springs, loose or damaged shoe hold-
down pins and springs Clean or deburr
Clean or replace
Correct or replace
Squealing. noise when ,rakes
are not applied Incorrect brake pedal or booster push rod
Bent or warped backing plate causing interference
with drum
Drum brakes-weak, damaged or incorrect shoe-to-
shoe spring Adjust
Replace
jquealing noise when Irakes
are not applied Poor return of brake booster or master cylinder or
wheel cylinder
Loose or extra parts in brakes Retighten
Improper positioning of pads in caliper
Improper installation of support mounting to caliper
body Correct
Improper machining of drum causing interference
with backing plate or shoe
Disc brakes-rusted, stuck
Worn, damaged or insufficiently lubricated wheel bearings Replace drum
Lubricate or replace
Incorrect brake pedal or booster push-rod Adjust
sroaning. clicking or rat-Stones or foreign material trapped inside wheel
Remove stones, etc.
ling noise when brakes covers
Ire not applied
Loose wheel nuts Retighten
Disc brakes-loose installation bolt
Worn, damaged or dry wheel bearings Disc brakes-failure of shim
Disc brakes-wear on sleeve Lubricate or replace
Replace
Incorrect brake pedal or booster push-rod Adjust
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SERVICE BRAKES - Anti-lock Braking System Troubleshooting35-15
ANTI-LOCK BRAKING SYSTEM
TROUBLESHOOTINGM35EElAE
PARTICULAR CHARACTERISTICS OF
THE ANTI-LOCK BRAKING SYSTEM
Models equipped with the anti-lock braking system
(A.B.S.) may exhibit one or more of the following
characteristics from time to time, but none of these
is abnormal.
(1)
(2)
A pulsing feeling in the brake pedal, or vibration
of the body or the steering wheel, when the
anti-lock braking system is activated by sudden
braking or by braking on a slippery road surface.
Actually, this phenomenon is an indication that
the anti-lock braking system is functioning nor-
mally.
When the vehicle speed reaches approximately
6 km/h (4 mph) after the engine is started and
the vehicle starts off (for the first time), awhining motor noise may be heard from the
engine compartment if the vehicle is traveling in
a quiet place. This noise is simply the result of a
self-check being made of the anti-lock braking
system operation.
TROUBLESHOOTING METHODS
Problems related to the anti-lock braking system
(A.B.S.) can be classified into two general categor-
ies: problems in the electrical system and those in
the hydraulic system. For problems in the electrical system, the on-board
diagnostic is built into the electronic control unit
(E.C.U.) causing the A.B.S. warning light to illuminate
as a warning to the driver. In this instance, checks
can be made by using the scan tool and oscillo-
scope.
Problems in the hydraulic system (poor braking,
etc.) can be located in the same way as for ordinary
brakes. There is, however, the necessity to check to
determine whether the problem is related to ordi-
nary brake components or to the components re-
lated to the A.B.S. To make this check, use the scan
tool.
HOW TO USE THE TROUBLESHOOTING
FLOW CHART
(1) Using the flow chart, check the ABS warning
light light-up sequence. Read the diagnostic
trouble codes and check the condition of bra-
king operation.
(2) Following the check chart listed in the remedy
column, perform the checks. There are [Expla- nation] and [Hint] in each check chart. Refer to
them when troubleshooting.
NOTE
ECU: Electronic control unit
HU:Hydraulic unit
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