1991 MITSUBISHI MONTERO parking brake

\003* B RAK E S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Brake Systems - Motorist Assurance Program
Standards For Automotive Repair
All Makes & Models
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCUMULATORS
ANCHOR PINS
ANTI-LOCK BRAKE SYSTEMS
BACKING PLATES
BRAKE FLUID
BRAKE FRICTION MATERIAL
BRAKE PADS
BRAKE PEDALS
BRAKE SHOES
BRAKE SHOE HARDWARE
BRAKE STOPLIGHT SWITCHES
BULB SOCKETS
BULBS AND LEDS
CALIPER HARDWARE
CALIPERS
CONTROLLERS
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)
DISABLE SWITCHES
DRUMS
ELECTRICAL PUMPS AND MOTORS
ELECTRONIC CONTROLLERS
FLUID
FLUID LEVEL SENSOR SWITCHES
FOUR WHEEL DRIVE SWITCHES
FRICTION MATERIAL
G SENSORS
HOSES
HYDRAULIC MODULATORS
HYDRO-BOOSTERS
HYDRO-ELECTRIC BOOSTERS (POWERMASTER)
IGNITION DISABLE SWITCHES
LATERAL ACCELERATION SWITCHES
LEDS
LENSES
MASTER CYLINDERS
MODULATORS
MOTORS
PARKING BRAKE SWITCHES
PARKING BRAKE SYSTEMS
PADS
PEDAL TRAVEL SWITCHES
PEDALS
POWERMASTER
PUMPS
PRESSURE DIFFERENTIAL SWITCHES
PRESSURE SWITCHES
RELAYS
ROTORS
SELF-ADJUSTING SYSTEMS

CALIPER INSPECTION








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Condition Code Procedure
Bleeder port damaged .... A ... Require repair or replacement
of caliper.
Bleeder screw broken off
in caliper ............. A ........... (1) Require repair or
replacement of caliper.
Bleeder screw plugged ... A ........... ( 1) Require repair or
replacement of bleeder screw.
Bleeder screw seized .... A ......... ( 2) Require replacement
of caliper.
Casting corroded,
affecting structural
integrity .............. A ............ Require replacement.
Casting damaged, affecting
structural integrity ... A ............ Require replacement.
Dust boot around caliper
torn ................... A ..... Require replacement of dust
boot.
Leaking ................. A .. Require repair or replacement.
Mounting pin threads
damaged ................ A ... Require repair or replacement
of component with damaged
threads.
Mounting pin threads
stripped in caliper
bracket (threads
missing) ............... A ... Require repair or replacement
of caliper bracket.
Mounting pin threads
stripped in steering
knuckle (threads
missing) ............... A ... Require repair or replacement
of steering knuckle.
Mounting pin threads
stripped (threads
missing) ............... A ... Require repair or replacement
of component with stripped
threads.
Parking brake cable
support, lever, or return
spring bent ............ A ... Require replacement of parts.
Parking brake cable
support, lever, or return
spring broken .......... A ... Require replacement of parts.
Parking brake mechanism in
caliper inoperative .... A .. Require repair or replacement.
Piston corroded (pitted
or peeling chrome
plating) ............... B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, affecting
performance ............ B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, not
affecting performance .. .. ........ No service suggested or
required.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement

(1) - This condition may be normal on some vehicles equipped with
anti-lock brakes.
( 2) - Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction
material wear.
( 3) - This condition may indicate contaminated brake fluid.
See BRAKE FLUID .









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MODULATORS
See HYDRAULIC MODULATORS .
MOTORS
See ELECTRICAL PUMPS AND MOTORS .
PARKING BRAKE SWITCHES
See SWITCHES.
PARKING BRAKE SYSTEMS
NOTE: The parking brake is an integral part of the brake
system. It is important that the parking brake function
properly when brake service is performed.
PARKING BRAKE SYSTEM 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.
Cable improperly
adjusted ............... B ....... Require cable adjustment.
Cable or individual
wires in the cable
are broken ............. A .... Require replacement of cable
assembly.
Cable sticking .......... A ...... Require cable lubrication.
Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly ..... A .... Require replacement of cable
assembly.
Inoperative ( 1) ......... A .......... Require replacement of
inoperative parts.
Parking brake
parts bent ............. B ... Require repair or replacement
of bent parts.
Parking brake
parts broken ........... A ... Require replacement of broken
parts.
Parking brake parts

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

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

Installation
To install, reverse removal procedure. Tighten wheel bearings
to 22 ft. lbs. (30 N.m). Loosen nut, and then retighten to 72 INCH
lbs. (8 N.m). Install cotter pin. If pin does not align, loosen nut up\
to a maximum of 30 degrees.
REAR BRAKE DRUM & SHOES
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Remove shoe return spring and brake shoe adjuster. See Fig. 8. Remove
adjusting spring, shoe retaining spring and shoe hold-down pins.
2) Remove shoe and lining assembly with parking brake lever.
Remove cable from parking lever. Remove parking brake lever snap ring,
and disengage lever from brake shoe.
Fig. 8: Exploded View of Rear Brake Assembly
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) To install, reverse removal procedure. Apply Lubriplate to
backing plate bosses, adjuster assembly threads and parking brake
lever pin.
2) Set adjustment assembly so brake shoes lightly contact
brake drum. Depress brake pedal to center shoes, and check pedal
travel. Rotate brake drum to ensure free movement.
WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES under REMOVAL & INSTALLATION. Remove wheel
cylinder and seal assembly. To install, reverse removal procedure.
Bleed brakes.
MASTER CYLINDER
Removal
Drain brake fluid from master cylinder. Remove sensor
connector (if equipped). Disconnect brake lines from master cylinder,
and install plugs to prevent brake fluid spillage. Remove master
cylinder from booster unit and separate reservoirs from housing (if
necessary).
Installation
To install, reverse removal procedure. Before installation,
check and adjust clearance between back of master cylinder piston and
power brake push rod. Refer to MASTER CYLINDER PUSH ROD under
ADJUSTMENTS. After installation, adjust the brake pedal height. Refer
to BRAKE PEDAL HEIGHT & FREE PLAY under ADJUSTMENTS. Bleed brake
system. See BLEEDING BRAKE SYSTEM .

cylinder. Disconnect parking brake cable end, and remove cable
attaching bolts. Remove brake backing plate, bearing case and axle
shaft as an assembly. If axle shaft binds, use slide hammer with
puller to remove.
2) Remove shims, "O" ring and snap ring. Retain shims for
reassembly. Secure axle shaft assembly in a vise, and remove one
retainer bolt from backing plate. Push bearing case completely to side
of dust cover. Place adhesive tape around edge of bearing case at
retainer bolt hole to prevent damage.
3) Secure axle shaft, and grind retainer ring until retainer
ring wall thickness is .04-.06" (1.0-1.5 mm) on axle shaft side and
retainer ring wall thickness is .08" (2.0 mm) on bearing side. See
Fig. 11.
CAUTION: DO NOT damage bearing case or axle shaft when grinding or
chiseling retainer ring.
4) Change angle of grind, and remove remaining .08" (2.0 mm)\
of retainer ring wall on bearing side. See Fig. 11. Using a chisel,
cut retainer ring, and remove. DO NOT damage axle shaft.
Fig. 11: Grinding Bearing Retainer Ring (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
5) Install Puller (MB990787-01) to remove bearing case from
axle shaft. Rotate nuts with equal force to remove wheel bearing.

CO M PU TE R R ELE A R N P R O CED URES

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Computer Relearn Procedures
All Models
* PLEASE READ THIS FIRST *
The following general procedures are to be used if
driveability problems are encountered after power loss or battery has
been disconnected. These procedures may provide an aid in eliminating
these problems.
To reduce the possibility of complaints, after any service
which requires battery power to be disconnected, vehicle should be
road tested.
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may
require a relearn procedure after vehicle battery is disconnected.
Many vehicle computers memorize and store vehicle operation patterns
for optimum driveability and performance. When vehicle battery is
disconnected, this memory is lost. The computer will use default data
until new data from each key start is stored. As computer memorizes
vehicle operation for each new key start, driveability is restored.
Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during
relearn stage because vehicle acts differently then before being
serviced. Depending on type and make of vehicle and how it is
equipped, the following complaints (driveability problems) may exist:
* Harsh Or Poor Shift Quality
* Rough Or Unstable Idle
* Hesitation Or Stumble
* Rich Or Lean Running
* Poor Fuel Mileage
These symptoms and complaints should disappear after a number
of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be
disconnected, vehicle should be road tested. If a specific relearn
procedure is not available, the following procedure may be used:
Automatic Transmission
* Set parking brake, start engine in "P" or "N" position.
Warm-up vehicle to normal operating temperature or until
cooling fan cycles.
* Allow vehicle to idle for one minute in "N" position. Select
"D" and allow engine to idle for one minute.
* Accelerate at normal throttle position (20-50%) until vehicle
shifts into top gear.
* Cruise at light to medium throttle.
* Decelerate to a stop, allowing vehicle to downshift, and use
brakes normally.
* Process may be repeated as necessary.
Manual Transmission