1991 MITSUBISHI ECLIPSE sensor

REAR AXLE - Specifications
ItemsLimit
Rear axle total backlash
Drive gear
runoutRear wheel bearing end play
Differential gear backlashSpecifications
mm (in.) 5
(.2)mm (in.) 0.05
(.002)mm (in.) 0.8
(.031)mm (in.) 0.2
(.008)
TORQUE SPECIFICATIONS
ItemsNmft.lbs.
Drive shaft to companion flange55-65
40-47Axle shaft installation nut
160-220116-159Rear brake assembly installation bolts
50-6036-43
Rear speed sensor brackets9-14
7-10Differential carrier to crossmember
100-12072-87
Differential carrier to propeller shaft
30-3522-25
Differential carrier to differential support
member80- 10058-72
Differential support member to bolt
110-13080-94Drain plug
60-7043-51
Filler plug40-6029-43
Companion flange to drive pinion
160-220116-159
Bearing cap installation bolt
40-6029-43
Drive to differential case
gear80-9058-65
Cover to carrier
gear30-4222-30
LUBRICANTS
ItemsRear axle gear oilSpecified lubricantsQuantity
MOPAR Hypoid Gear Oil API classification
GL-5 or higher0.7 lit. (0.74 qts.Above
-23°C (-10°F) SAE 90, 85W-90, 8OW-90From
-34°C (-30°F) to -23°C (-10°F) SAE 8OW, 8OW-90Below
-34°C (-30°F) SAE 75WB.J. boot grease
D.O.J. boot greaseRepair kit grease90
g (3.2 dz.)Seal lip of outer bearingMOPAR Multi-Mileage Lubricant Part No.2525035 or equivalent As required
Trailing arm oil seal lip
Oil seal lip of side bearing
Washer of special tool
(M B990836)Oil seal lip of drive pinion
Differential companion
flange washer
SEALANTS AND ADHESIVES
..-
ItemsSpecified sealants and adhesivesIVent plug
Differential cover3M ATD Part
No.8661, 8663 or equivalent
Drive gear threaded holeMOPAR Part
No.4318031 or 4318032 or equivalent

3-10REAR AXLE - Axle Shaft
AXLE SHAFT
REMOVAL AND INSTALLATION
Pre-removal Operation
*Disconnecting of Parking Brake Cable
End9-14 Nm
7-W ft.lbs.55-65Nm
40-47ft.lbs.160-220Nm
!116- 159 Ift.lbs.50-60 36-43ft.lbs. Nm
Removal steps
4*1. Rear speed sensor 2. O-ring
c*3. Brake caliper assembly4. Brake disc
/llA03604
5. Drive shaft mounting nut
+e l +6. Self-locking nut
7. Washer
8. Companion flange
c+9. Axle shaft assembly4I) +4 10. Rear rotor +e ++ 11. Outer bearing*e ++ 12. Dust cover++ 13. Dust cover
14. Axle shaft
4* +4 15. Oil seal+e l + 16. Inner bearing
NOTE(1) Reverse the removal procedures to reinstall.
(2)
*I) : Refer to “Service Points of Removal”.
(3) l + : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts
ALNOBHA-Post-installation Operation
Konnecting of Parking Brake Cable EndaAdjusting Parking Brake Lever
Stroke (Refer to GROUP
5-ServiceAdjustment Procedures.)
SERVICE POINTS OF REMOVAL
NOBHBAP
1.REMOVAL OF REAR SPEED SENSOR ABS>NOTE
Be cautious to ensure that the tip of the pole piece does not
Acome in contact with other parts when removing the speed
csensor.
3. REMOVAL OF BRAKE CALIPER ASSEMBLY
Remove the brake caliper assembly and suspend it with a
piece of wire.

BRAKES
SERVICE AND PARKING
CONTENTS
ANTI-LOCK BRAKING SYSTEM
TROUBLESHOOTING
......................................
9
BRAKEBOOSTER...........................................
60BRAKE LINE
....................................................
62
BRAKE PEDAL.................................................
53ELECTRONIC CONTROL UNIT
ABS>...............................87
- FRONT DISC BRAKE......................................
65G-SENSOR
..............................86
HYDRAULIC UNIT
ABS>...............................
77
MASTERCYLINDER
........................................56
PARKING BRAKES
..........................................88
REAR
DISC BRAKE.........................................70SERVICE ADJUSTMENT PROCEDURES..
.....41
ABSPowerRelayCheck.............................52
Bleeding........................................................
45Brake Booster Operating
Inspection...........43
BrakeFluidLevelSensor Check.................
42Brake Pedal Inspection and Adjustment
.....41Check Valve
OperationCheck.....................
44
FlatBattery
Remedy....................................52
FrontBrakeDiscRun-out Check................47Front Brake Disc Run-out Correction
..........48Front Brake
Disc Thickness Check
.............47Front Disc Brake Pad Check and
Replacement.................................................46
Parking
BrakeLever Stroke Check.............42
Parking
BrakeSwitchCheck.......................43
Proportioning
ValveFunctionTest...............44Rear Brake
DiscRun-out Check.................50Rear Brake Disc Run-out Correction
...........50Rear Brake
Disc Thickness
Check..............49Rear Disc Brake Pad Check and
Replacement.................................................48Observation of Wheel Speed Sensor
Output Voltage Variations
with
ABS>..................................51
SPECIAL TOOLS.............................................6
SPECIFICATIONS.............................................
2General Specifications
..................................2
Lubricants
......................................................5
Service
Specifications...................................4
Torque
Specifications...................................4
TROUBLESHOOTING......................................7WHEEL SPEED SENSOR
...............................80
_ CAUTION
When servicing brake assemblies or components, do not create dust by sanding, grinding or by cleaning
brake parts with a dry brush or with compressed air. A WATER DAMPENED CLOTH SHOULD BE USED.
Many brake components contain asbestos fibers which can become air-borne if dust is created duringservice operations. Breathing dust which contains asbestos fibers can cause serious bodily harm.

5-2BRAKES - SDecifications
SPECIFICATIONS
GENERAL SPECIFICATIONS

NO!iCA-- -
ItemsItems
NNVehicles without ABS Vehicles without ABSVehicles with ABS Vehicles with ABS
BIBI
PlPl
Fr Frlaster cylinder
TypeTandem typeTandem type
(with level sensor)(with level sensor)
I.D.mm (in.) 22.2 (7/8)23.8 (‘%6)rake booster
TypeVacuum typeVacuum type
Effective dia. of power cylinder
mm (in.) 230 (9.0)Front side: 180 (7.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.0 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]
.oportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
4,200 (597)
Decompression ratio
0.3
0.3ont brakes
TypeFloating caliper, single-piston,ventilated disc (M-R44V)Floating caliper, single-piston,ventilated disc (M-R44V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thicknessmm (in.) 16.0 (63)
16.0
(.63)Wheel cylinder I.D.
mm (in.) 53.9 (2
l/8)53.9 (2%)
Clearance adjustmentAutomaticAutomatic
3ar disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD30P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)
Disc thickness
mm (in.)
10 (39)10 i.39)Pad thickness
mm (in.) 14.5 (57)
14.5 (57)
Wheel cylinder I.D.
mm (in.) 30.1
(1 3/16)30.1 (1 346)Clearance adjustment
AutomaticAutomatic
)tor teeth
Front wheel side
-47Rear wheel side
-47
leed sensor-Magnet coil type
rking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever type
Lever type
Lever type
Cable arrangement
V-type
V-type
Rc Rc
SP SP
Pa Pa

-.
BRAKES - Specifications5-3
ItemsFWDAWDMaster cylinder
TypeTandem type
(with level sensor)Tandem type
(with level sensor)
I.D.mm (in.) 23.8 (‘%a)25.4 (1)Brake booster
TypeVacuum type
Vacuum type
Effective dia. of power cylinder
mm (in.) Front side: 180 (7.0)
Front side: 180 (7.0)
Rear side: 205 (8.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.5 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]Proportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
3,700 (526)
Decompression ratio
0.30.3Front brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (M-R44V)ventilated disc (M-R46V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thickness
mm (in.) 16.0
(.63)16.0 (.63)Wheel cylinder I.D.
mm (in.)
53.9 (2 ‘16)60.3 (23%3)Clearance adjustment
AutomaticAutomatic
Rear disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD35P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)Disc thicknessmm (in.) 10
(.39)10 f.39)Pad thicknessmm (in.) 14.5
(.57)14.5 (.57)Wheel cylinder I.D.mm (in.) 30.1 (1
3/16)34.9 (1 3h)Clearance adjustmentAutomaticAutomatic
qotor teeth*
Front wheel side
4747Rear wheel side
4747
speed sensor*Magnet coil typeMagnet coil type‘arking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever typeLever typeLever type
Cable arrangementV-typeV-type
NOTEThe *symbol indicates vehicles with ABS.

5-4BRAKES - Specifications
SERVICE SPECIFICATIONS
NO5CB-
ItemsSpecifications
Standard value
Brake pedal heightmm (in.) 176-181 (6.9-7.1)
Brake pedal free playmm (in.) 3-8
(l-.3)Brake pedal to floorboard clearance
mm (in.) 80 (3.1) or more
Parking brake lever stroke
5-7 notches
Output pressure proportioning valve
MPa (psi)
Split point
3.95-4.45 (561-633)
3.45-3.95 (491-561)
Output pressure [input pressure]
5.15-5.65 (732-804) [8.2 (1 ,I 63)l
4.65-5.15 (661-732) (7.7 (1,095)1Disc brake dragging force at hub bolt
N (Ibs.) [Nm (ftlbs.)]70 (15) or less [4 (3) or less1Booster push rod to master cylinder piston clearance
mm (in.)
9 inch brake booster
0.8-l .O (.031-,039)
7
+8 inch brake booster0.5-0.7 (.020-.028)
Speed sensor’s internal resistance
kQ 0.8-l .2*
Clearance between the speed pole piece and
the toothed rotor
mm (in.)
0.3-0.9 (.012-,035)”Limit
Left/right proportioning valve out pressure difference
MPa (psi)0.4 (57)
Disc brake pad thickness
mm (in.) 2.0 (08)
Front disc thickness
mm (in.) 22.4 (882)
Rear disc thickness
mm (in.) 8.4
(.331)Disc
runoutmm (in.) 0.08 (.0031)Hub end play
mm (in.) 0.008
(.00031)
NOTE
*: Vehicles with ABS
TORQUE SPECIFICATIONS
ItemsNmft.lbs.
Pedal support bracket installation bolts
8-12
6-9
Pedal support bracket installation nut
IO-157-11
Pedal rod to pedal support bracket
17-26
12-19
Pedal rod to clutch pedal bracket
17-26
12-19
Clutch pedal bracket installation bolt
8-12
6-9
Turn-over spring mounting bolt
17-26
12-19
Stop lamp switch mounting nut
IO-157-l 1‘Clutch master cylinder installation nuts
10-157-11
Clutch pedal installation nut
20-2514-18
Lever assembly (A) installation nut
20-2514-18
Lever assembly
(B) installation nut20-2514-18

BRAKES - Specifications5-5Items
Nmftlbs.Master cylinder to brake booster
8-126-9
Piston stopper bolt
1.5-3.0l-2Nipple installation screw
1.5-3.0l-2Brake booster installation nuts
11-178-12
Fitting15-1811-13
Flared brake line nuts
13-179-12
Brake hose bracket installation bolts
17-2612-19
Front disc brake assembly installation bolts
80-10058-72
Lock pin (front)
64-8646-62
Guide pin (front)
64-8646-62
Bleeder screw
7-95-7
Wheel bearing nut
200-260144-188
Dust shield to axle beam
9-14
7-10Rear disc brake assembly installation bolts
50-6036-43
Drive shaft to companion flange
55-6539-47
companion flange to rear axle shaft160-200116-159
Brake hose to caliper body (rear)
25-35
18-25Lock
pin (rear)
22-3216-23
Guide pin (rear)
22-32
16-23Spindle lever to parking brake lever
40-5529-40
3ear speed sensor installation bolt
9-147-10Speed sensor bracket installation bolt
9-14
7-10
3otor to front hub
7-115-8
3otor to rear hub
9-147-10
LUBRICANTSNO5CP-
ItemsBrake fluidSpecified lubricant
MOPAR Brake
Fluid/Conforming to
DOT3Brake pedal bushing inner surface
Clevis pin and washer
Parking brake lever sliding parts
Bushing inner surfaceMOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent

BRAKES - Anti-lock Braking System Troubleshooting5-14
./
No.Trouble conditionMajor causesRemedyAfter the ignition key is turned to the
l Break in harness for ECU warningCheck, usinflow
“ON” position, it blinks once and then
light drive circuit
chart D. (Re er to9illuminates when it is turned to the
l Malfunction of ECUP.5-18.)“START” position. When the key is
4returned to the “ON” position, the light
blinks again. (Blinking with the ignition
key in the “ON” position is synchronized
with operation noise of the valve relay.)
ABSwarninglighto:-
Ignition
keyACC. LCi+-
14*0593CONTINUED FROM PREVIOUS PAGE
Does the ABS warning light illuminate
when starting to drive the car?
Yes~ Trouble with the motor re-lay, solenoid valve [due toL Check, following trouble
source check charts E-l -self test when driving above
E-6.6 km/h (4 mph)] or malfunc-
NoIs there one-sided braking, insufficient
braking force or malfunction of ABS
operation?
YesTrouble condition
Major causes
One-sided braking
Insufficient braking forcel Mechanical lock of HU solenoid valve
l Hydraulic line in HU is clogged.
Decline in ABS function
(Wheels easily lock when there is sud-
den braking.)
ABS sometimes functions even when
there is no sudden braking. (ABS opera-
tion vibration is transmitted.)
1 tion of wheel speed sensor 1
NoNormall Malfunction in HU solenoid valve op-
erationl Hydraulic line in HU is clogged.
l Insufficient wheel speed sensor out-
put voltage (sensor malfunction, too
large a gap between sensor rotor,
missing rotor teeth or temporarily
broken wire in sensor harness)
l Malfunction of ABS ECU
RemedyCheck HU operation and, if
necessary, replace HU.
If HU is normal, check
structural parts for normal
braking. (Refer to
P.5-7.)Check wheel speed sensor
(Refer to
P.5-82.) and, ifnecessary,replace sensor,
adjust gap or replace rotor.
If tests indicate that there are
no mechanical or electrical
failures, replace the ECU.