1991 MITSUBISHI MONTERO brake
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missing ................ C .. Require replacement of missing
parts.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
(1) - Inoperative includes intermittent operation.
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PADS
See FRICTION MATERIAL .
PEDAL TRAVEL SWITCHES
See SWITCHES.
PEDALS
See BRAKE PEDALS.
POWERMASTER
See HYDRO-BOOSTERS .
PUMPS
See ELECTRICAL PUMPS AND MOTORS .
PRESSURE DIFFERENTIAL SWITCHES
See SWITCHES.
PRESSURE SWITCHES
See SWITCHES.
RELAYS
NOTE: Copied from Electrical UIGs
RELAY INSPECTION
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Housing broken .......... A ............ Require replacement.
Housing cracked ......... 2 ............ Suggest replacement.
Inoperative ( 1) ......... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned,
affecting performance .. A ........... ( 2) Require repair or
replacement.
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reconditioning ......... B ........ (3) Require replacement.
Surface is rust-pitted .. B ....... Require reconditioning or
replacement of rotor according
to OEM specifications.
Surface is scored ....... B ... ( 4) Require reconditioning or
replacement of rotor according
to OEM specifications.
Thickness variation
(parallelism) exceeds OEM
specifications .......... B ....... Require reconditioning or
replacement of rotor according
to OEM specifications.
( 1) - Examples of severe corrosion are: composite plate
separated from friction surfaces and cooling fins
cracked or missing.
( 2) - Only applies to vehicles for which OEM "machine to"
specifications exist. If OEM does not supply "machine
to" specifications, the rotor may be worn to discard
specifications.
( 3) - If OEM does not supply "machine to" specifications,
you may machine to discard specifications.
( 4) - Scoring is defined as grooves or ridges in the friction
contact surface. Some vehicle manufacturers require
machining when scoring exceeds their allowable
specifications.
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SELF-ADJUSTING SYSTEMS
SELF-ADJUSTING SYSTEM INSPECTION \
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Condition Code Procedure
Bent .................... A ... Require repair or replacement
of bent part.
Broken .................. A ... Require repair or replacement
of broken part.
Inoperative ............. A ........... ( 1) Require repair or
replacement of inoperative
parts.
Missing ................. C .......... Require replacement of
missing part.
Star wheel does not turn
freely ................. A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation.
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SHOE HARDWARE
See BRAKE SHOE HARDWARE .
SHOES
See FRICTION MATERIAL .
SOCKETS
See BULB SOCKETS.
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
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specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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STEEL BRAKE LINES
STEEL BRAKE LINE INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 208 of 1333
BRAK E S YSTE M
1991 M it s u bis h i M onte ro
1991 BRAKES
Disc & Drum
Chrysler Motors: Ram-50;
Mitsubishi: Montero, Pickup
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake unit, proportioning valve and self-adjusting assembly. Pickup
and Ram-50 models have a Load-Sensing Proportioning Valve (LSPV). All
models are equipped with front disc brakes and rear drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Montero
Bleed brake system in following order: right rear, right
front and left front (one circuit handles both rear brakes).
Pickup & Ram-50
Bleed brake system in following order: right rear, left rear,
LSPV, right front and left front.
ADJUSTMENTS
BRAKE PEDAL HEIGHT & FREE PLAY
1) Separate connector from stoplight switch, and loosen lock
nut. Position switch so it does not contact brake pedal arm. Adjust
brake pedal height by rotating master cylinder push rod (yoke, if
equipped) until distance from top of brake pedal to floor board is
correct. See BRAKE PEDAL SPECIFICATIONS table.
2) DO NOT depress push rod. Tighten lock nut, and ensure
brake pedal height is within specification. Start engine to evacuate
brake booster chamber. Stop engine, and apply brake several times to
remove vacuum from brake booster.
3) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. If distance is incorrect, bleed the
brake hydraulic system, and check for misadjusted brakes. Refer to the
BRAKE PEDAL SPECIFICATIONS table.
BRAKE PEDAL SPECIFICATIONS TABLE
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Free Play Pedal Height
Application In. (mm) In. (mm)
Montero ............ .12-.31 (3-8) ... 7.5-7.7 (191-196)
Pickup & Ram-50 .... .12-.31 (3-8) ........... 6.5 (166)
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LOAD-SENSING PROPORTIONING VALVE (LSPV) (Pickup & Ram-50)
Park vehicle on level surface. Remove all luggage and
passengers. Ensure lever is not against stopper bolt. Check spring
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length. If spring length is not 6.97-7.09 in. (177-180 mm), adjust
cable or support until correct length is obtained. See Fig. 1.
Fig. 1: Testing LSPV Spring Length (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
MASTER CYLINDER PUSH ROD
Check and adjust clearance between back of master cylinder
piston and power brake push rod. See PUSH ROD CLEARANCE SPECIFICATIONS
table. See Fig. 2. After adjusting push rod clearance, adjust pedal
height, and bleed brake system.
Fig. 2: Adjusting Push Rod Clearance
Courtesy of Mitsubishi Motor Sales of America.
PUSH ROD CLEARANCE SPECIFICATIONS TABLE
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Page 210 of 1333
Application In. (mm)
Montero .............................. .004-.020 (0.1-0.5)
Pickup & Ram-50 ..................... .028-.043 (0.7-1.09)
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PARKING/EMERGENCY BRAKE
NOTE: Adjust service brake before adjusting parking brake.
Montero
1) Start engine, and apply brake pedal. Pull parking brake
lever with a force of 44-45 lbs. (20.0-20.4 kg). Parking brake lever
should move up 4-6 notches.
2) If necessary, turn adjusting cable nut located under
console or at end of cable rod. See Fig. 3.
Fig. 3: Adjusting Parking/Emergency Brake (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Pickup & Ram-50
Fully release parking brake, and allow slack in rear cable to
prevent brake shoe drag. Adjust turnbuckle for 2WD models (turn
adjusting nut on equalizer for 4WD models) to obtain a brake lever
stroke of 16-17 notches with a force of 66 lbs. (29.9 kg). Ensure
equalizer is at right angle to joint.
REAR DRUM BRAKE SHOES
Set adjustment assembly so brake shoes outside diameter is 9.
97-9.98 in. (253.2-253.5 mm). After brake drum installation, depress
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brake pedal to center shoes, and check pedal travel. Rotate brake drum
to verify free movement.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
.02-.04" (.5-1.0 mm). Tighten lock nut. DO NOT depress master cylinder
push rod during stoplight switch adjustment.
TESTING
POWER BRAKE UNIT
Check Valve Inspection
Remove vacuum hose from power brake unit. Remove check valve
from hose (if possible). Using a vacuum pump, ensure airflow is in
direction of intake manifold only.
System Check
1) Run engine for 2 minutes, and shut it off. Depress brake
pedal several times with normal pressure. If pedal height gradually
becomes higher with successive applications, power brake unit is okay.
If pedal height remains steady, power brake unit is faulty.
2) With engine stopped, depress brake pedal repeatedly until
it's height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake unit is okay. If pedal
height does not change, power brake unit is faulty.
3) With engine running, press and hold brake pedal and shut
off engine. Hold brake pedal for 30 seconds. Brake pedal height should
not change. If pedal height falls, power brake unit is faulty.
LOAD-SENSING PROPORTIONING VALVE (LSPV) (PICKUP & RAM-50)
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
,
ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, perform LSPV
test beginning with next step.
2) Ensure unladen vehicle is on level ground. Ensure lever is
not contacting stopper bolt. See Fig. 1.
3) When lever is pushed toward valve, distance from LSPV
lever hole and support hole must be 6.97-7.09 in. (177-180 mm). If
measured distance is not within specification, loosen support bolt.
Adjust support until measured distance is within specification.
4) After measured distance is within specification, connect
pressure gauges to input and output ports of LSPV. See Fig. 4. Bleed
brake system. See BLEEDING BRAKE SYSTEM .
Fig. 4: Connecting Pressure Gauges to LSPV (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
Page 212 of 1333
5) Remove the LSPV load-sensing spring. Slowly depress the
brake pedal. Check the readings on the pressure gauges. Refer to the
LSPV PRESSURE SPECIFICATIONS table.
6) Install LSPV load-sensing spring. Load weight into rear of
vehicle until measured spring length distance is 7.0" (178 mm) with
lever slightly pressed in. See Fig. 1.
7) Slowly depress brake pedal. Check readings on pressure
gauges. See LSPV PRESSURE SPECIFICATIONS table. If fluid pressure is
not within specification, ensure all other brake system components are
okay. If other components are okay, replace LSPV assembly.
LSPV PRESSURE SPECIFICATIONS (PICKUP & RAM-50)
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Application Inlet Pressure Outlet Pressure
psi (kg/cm) psi (kg/cm)
Load-Sensing Spring
Removed ........... 853 (60) ......... 242-327 (17-23)
Installed ........ 1991 (140) .... ( 1) 299-583 (21-40)
( 1) - On vehicles with 2WD and heavy-duty suspension,
outlet pressure is 526-697 psi (37-49 kg/cm
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PROPORTIONING VALVE (NON-LOAD-SENSING) (MONTERO)
Pressure Test
1) Connect pressure gauges to input and output ports of the
proportioning valve. See Fig. 5. Bleed brake hydraulic system. Refer
to BLEEDING BRAKE SYSTEM .
2) Slowly depress brake pedal. Check readings on pressure
gauges. See the PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. If
fluid pressures are not within specification, replace proportioning
valve.
Fig. 5: Connecting Pressure Gauges to Proportioning Valve (Typical)
Courtesy of Mitsubishi Motor Sales of America.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (MONTERO)
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