1997 MITSUBISHI TRITON brake

BASIC BRAKE SYSTEM ± General Information35A-3
GENERAL INFORMATION35100010120
The brake system has high reliability and durability
which maintains excellent braking performance and
braking feeling. The main features are as follows.

A dual type master cylinder is equipped in all
models.

Both a single type and a tandem type brake
booster have been adopted.
The following type of brake have been adopted.
Front: Floating caliper, 2-piston, ventilated disc
brakes (V4-W43, V5-W43) or floating caliper,
1-piston, ventilated disc brakes (V4-S60,
V5-S60)
Rear: Leading-trailing type drum brake.
Items2WD
vehicles>2WD
vehicles>4WD
vehicles>4WD
vehicles>
Master cylinder I.D. mm23.823.823.823.8
Brake booster effective dia.
of power cylinder mm230
205 + 230*230
180 + 205*205 + 230180 + 205
Brake booster boosting ratio5.05.07.07.0
Load sensing proportioning
valve decompression ratio0.150.150.150.15
Front brake disc effective
dia. mm200200222
228*222
228*
Front brake wheel cylinder
I.D. mm60.3
42.9*60.3
42.9*60.3
42.9*60.3
42.9*
Rear drum brake drum I.D.
mm254254270270
Rear drum brake wheel
cylinder I.D. mm23.823.823.823.8
Rear drum brake lining
thickness mm4.74.74.74.7
NOTE
*: Vehicles with ABS.

BASIC BRAKE SYSTEM ± Service Specifications35A-5
SERVICE SPECIFICATIONS35100030119
ItemsStandard valueLimit
Brake pedal height mm176 ± 181±
Brake pedal free play mm3 ± 8±
Brake pedal to floor board clearance mm95 or more±
Load sensing proportioning
valve outputpressure kPa
2WDWhen load sensing
spring length is 190
3,625 (5,884)±
valve out ut ressure kPa
(Input pressure kPa)
s ring length is 190
mm (when unladen)5,390 (17,652)±
When load sensing
spring length is 215
mm (when laden)14,393 (17,652)±
4WDWhen load sensing
spring length is 190
4,309 (5,884)±
s ring length is 190
mm (when unladen)6,074 (17,652)±
When load sensing
spring length is 215
mm (when laden)16,310 (17,652)±
Load sensing spring length mm189 ± 193±
Booster push rod to master
cylinder piston clearance mmSingle brake boosterPetrol-powered ve-
hicles0.65 ± 1.05±
Diesel-powered ve-
hicles1.00 ± 1.40±
Tandem brake boosterVehicle which brake
booster of power
cylinder is 180 mm
and 205 mm in
effective diameter0.90 ± 1.30±
Vehicle which brake
booster of power
cylinder is 205 mm
and 230 mm in
effective diameter0.70 ± 1.10±
Front disc brake pad thickness mm102.0
Front brake disc thickness mm2422.4
Front brake disc run-out mm2WD±0.08
4WD±0,06
Front disc brake drag force (tangential force of wheel mounting bolts) N69 or less±
Rear drum brake lining thickness mm4.71.0
Rear drum inside diameter mm2WD254.0256.0
4WD270.0272.0
Front hub end play mm0.05±

BASIC BRAKE SYSTEM ± Troubleshooting35A-7
TROUBLESHOOTING35100070081
SymptomProbable causeRemedy
Vehicle pulls to one side
when brakes are applied
Grease or oil on pad or lining surfaceReplace
when brakes are a lied
Inadequate contact of pad or liningCorrect
Auto adjuster malfunctionAdjust
Drum eccentricity or uneven wearRepair or replace as necessary
Insufficient braking powerLow or deteriorated brake fluidRefill or change
Air in brake systemBleed air
Overheated brake rotor due to dragging of pad
or liningCorrect
Inadequate contact of pad or lining
Brake booster malfunction
Clogged brake line
Grease or oil on pad or lining surfaceReplace
Load sensing proportioning valve malfunction
Auto adjuster malfunctionAdjust
Increased pedal stroke
(Reducedpedal to floor
Air in brake systemBleed air
(Reduced edal to floor
board clearance)Worn lining or padReplace
Broken vacuum hose
Faulty master cylinder
Brake fluid leaksCorrect
Auto adjuster malfunctionAdjust
Excessive push rod to master cylinder
clearance
Brake dragIncomplete release of parking brakeCorrect
Clogged master cylinder return port
Incorrect parking brake adjustmentAdjust
Improper push rod to master cylinder
clearance
Faulty master cylinder piston return springReplace
Worn brake pedal return spring
Broken rear drum brake shoe to shoe spring
Lack of lubrication in sliding partsLubricate

BASIC BRAKE SYSTEM ± Troubleshooting35A-8
SymptomProbable causeRemedy
Insufficient parking brake functionWorn brake lining or padReplace
Grease or oil on lining or pad surface
Parking brake cable sticking
Stuck wheel cylinder or caliper piston
Excessive parking brake lever strokeAdjust the parking brake lever stroke or
check the parking brake cable routing
Auto adjuster malfunctionAdjust
Scraping or grinding noise when
brakes are applied
Worn brake lining or padReplace
brakes are a lied
Caliper to wheel interferenceCorrect or replace
Dust cover to disc interference
Bent brake backing plate
Cracked drums or brake disc
Squealing, groaning or chattering
noise when brakes are appliedDisc brakes ± Missing or damaged
brake pad anti-squeak shimReplace
Brake drums and linings, discs and pads
worn or scoredCorrect or replace
Improper lining parts
Disc brake ± Burred or rusted calipersCorrect or deburr
Dirty, greased, contaminated or glazed
liningsClean or replace
Drum brakes ± Weak, damaged or
incorrect shoe hold-down springs, loose
or damaged shoe hold-down pins and
springsCorrect or replace
Incorrect brake pedal or booster push rodAdjust

BASIC BRAKE SYSTEM ± Troubleshooting35A-9
SymptomProbable causeRemedy
Squealing noise
when brakes are
Bent or warped backing plate causing interference with drumReplace
when brakes are
not appliedDrum brakes ± Weak, damaged or incorrect shoe-to-shoe
spring
Poor return of brake booster, master cylinder or wheel
cylinder
Loose or extra parts in brakesRetighten
Improper positioning of pads in caliperCorrect
Improper installation of support mounting to caliper body
Improper machining of drum causing interference with
backing plate or shoeReplace drum
Disc brakes ± Rusted, stuckLubricate or replace
Worn, damaged or insufficiently lubricated wheel bearings
Incorrect brake pedal or booster push rodAdjust
Groaning, clicking or
rattling noise when
Stones or foreign material trapped inside wheel coversRemove stones, etc.
rattling noise when
brakes are not appliedLoose wheel nutsRetighten
Disc brakes ± Loose installation bolts
Worn, damaged or dry wheel bearingsLubricate or replace
Disc brakes ± Failure of shimReplace
Disc brakes ± Wear on sleeve
Incorrect brake pedal or booster push rodAdjust

35B-2
Bleeding 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Fluid Level Sensor Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Sensing Spring Length Check and
Adjustment Refer to GROUP 35A. . . . . . . . . . . . . . .
Load Sensing Proportioning Valve Function
Test Refer to GROUP 35A. . . . . . . . . . . . . . . . . . . . .
Disc Brake Pad Check and Replacement 23. . . . .
Front Disc Brake Rotor Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining Thickness Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Drum Inside Diameter Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining and Brake Drum Connection Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage Check
24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Unit Check 26. . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valve Check 27. . . . . . . . . . . . . . . . . . . . . . .
Motor Operation Check 27. . . . . . . . . . . . . . . . . . . . . . Motor Relay and Valve Relay Continuity
Check 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remedy for a Flat Battery 28. . . . . . . . . . . . . . . . . . .
BRAKE PEDAL Refer to GROUP 35A. . . . . . . .
MASTER CYLINDER AND BRAKE
BOOSTER 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING VALVE
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKE 32. . . . . . . . . . . . . . . . . . . . .
REAR DRUM BRAKE
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC UNIT 37. . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL SPEED SENSOR 39. . . . . . . . . . . . . . . . . .
ABS-ECU 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABS <2WD> ± Troubleshooting35B-5
TROUBLESHOOTING35201110143
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
PhenomenonExplanation of phenomenon
System check soundWhen starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being
performed, and is not an abnormality.
ABS operation sound1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
ABS operation
(Long braking distance)For road surfaces such as snow-covered roads and gravel roads, the braking distance for
vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise
the customer to drive safely on such roads by lowering the vehicle speed and not being too
overconfident.
Shock during system
operation checkShock may be felt when the brake pedal is depressed slightly at a low driving speed. This
occurs due to ABS operation check (initial check at a vehicle speed of 8 km/h), and does
not indicate any malfunction.
Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the ªCommentº are satisfied when checking the trouble
symptom again.
DIAGNOSIS FUNCTION35201120108
DIAGNOSIS CODES CHECK
Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP 00 ± How to Use Troubleshooting/Inspection
Service Points.)
ERASING DIAGNOSIS CODES
Refer to GROUP 00 ± How to Use Troubleshooting/Inspection
Service Points.

ABS <2WD> ± Troubleshooting35B-14
INSPECTION CHART FOR TROUBLE SYMPTOMS35201140142
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptomsInspection
procedure No.Reference
page
Communication with MUT-II
is notpossible
Communication with all systems is not possible.135B-15
is not ossible.
Communication with ABS only is not possible.235B-15
When the ignition key is turned to ªONº (engine stopped), the ABS warning lamp does
not illuminate.335B-16
After the engine starts, the ABS warning lamp remains illuminated.435B-16
When the ignition key is turned to ªSTARTº, the ABS warning lamp does not illuminate.535B-17
After the ignition key is turned to ªONº, the ABS warning lamp blinks twice, and when
turned to ªSTARTº, it illuminates. When returned to ªONº, the lamp flashes once, and
then switches off.635B-17
Faulty ABS operationUnequal braking power on both sides735B-18
Insufficient braking power
ABS operates under normal braking conditions
ABS operates before vehicle stops under normal
braking conditions
Large brake pedal vibration (Caution 2.)±±
Caution
1. If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.