Page 479 of 1310

REAR AXLE ± Service Specifications27-4
SERVICE SPECIFICATIONS27100030121
ItemStandard valueLimit
Rear axle total backlash mm±5
Axle shaft axial play mmVehicles without ABS or rear differential lock0.05 ± 0.20±
Vehicles with ABS or rear differential lock0 ± 0.25±
Limited slip differential
p
reload Nm
Using special tool13 or more±
reload Nm
Without using special tool25 or more±
Axle shaft retainer
press-fitting force NVehicles without ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
78,000±
Vehicles with ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
98,000 ± 108,000±
Clearance between axle shaft retainer and snap ring mm0 ± 0.166±
Rear differential lock air pump pressure kPa25 ± 40±
Drive gear backlash mm2WD0.08 ± 0.13±
4WD0.13 ± 0.18±
Drive gear runout mm±0.05
Differential gear backlash mm2WD0 ± 0.250.2
4WD0 ± 0.0760.2
Limited slip differential
starting torque Nm
When a new clutch plate is used39 ± 74±
starting torque Nm
When re-installing current clutch plate25 ± 74±
Drive pinion
turning torque NmWithout oil sealWhen replacing
(with anti-rust agent)0.6 ± 0.9±
When replacing or reusing
(with gear oil applied)0.4 ± 0.5±
With oil sealWhen replacing
(with anti-rust agent)0.8 ± 1.1±
When replacing or
reusing (with gear oil applied)0.6 ± 0.7±
Page 480 of 1310

REAR AXLE ± Service Specifications/Lubricants/Sealants27-5
ItemStandard valueLimit
Horizontal difference between friction plate and friction disc thickness mm0 ± 0.05±
Clearance between friction plate and friction disc mm0.06 ± 0.20±
Clearance in side gear axial direction mm0.05 ± 0.20±
Difference between left and right dimensions from back thrust face of pressure
ring to end of thrust washer mm0 ± 0.05±
Friction plate and friction disc warping (flatness) mm±0.08
Friction plate and friction disc wear
(difference in the thickness of the friction surface and the projections) mm±0.1
LUBRICANTS27100040049
ItemSpecified lubricantsQuantity
Rear differential gear oilConventional differential:
Hypoid gear oil
API classification GL-5 or higher SAE viscosity No. 90,
80 W
Limited slipdifferential:
2WD1.6
Limited sli differential:
Hypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 8149630 EX
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL-5, SAE 80W-90) or equivalent4WD2.6
SEALANTS27100050042
ItemsSpecified sealantsRemarks
Bearing case3M ATD Part No. 8661 or equivalentSemi-drying sealant
Dust cover
Axle housing (differential carrier mounting part)
Drive gear and differential case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant
Page 529 of 1310
WHEEL AND TYRE ± General Information/Service Specifications31-2
GENERAL INFORMATION31100010146
Both steel type and aluminium type wheels have
been adopted. The type of wheel used depends
on the vehicle model.
Items2WD4WD
WheelTypeSteel typeSteel typeAluminium type
Size14 x 6JJ16 x 6JJ15 x 7JJ
Amount of wheel offset333310 +1
Pitch circle diameter
(P.C.D.) mm139.7139.7139.7
TyreSize185R 14C 8PR205/80 R16 RF31 x 10.50 R15 LT
SERVICE SPECIFICATIONS31100030036
ItemsLimit
Tread depth of tyre mm1.6
Wheel runout (Radial runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less
Wheel runout (Lateral runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less
Page 544 of 1310
FRONT SUSPENSION ± Service Specifications/Sealant33A-3
SERVICE SPECIFICATIONS33200030088
ItemsStandard valueLimit
Toe-inAt the centre of tyre thread mm0 ± 7±
Toe-angle
(per wheel)
2WD0 ± 019'±
(er wheel)
4WD
205/80 R16 tyre>0 ± 016'±
4WD
x 10.50 R15 tyre>0 ± 015'±
Camber010' ± 110' (Difference between
right and left within 30')±
Caster2WD145' ± 345' (Difference between
right and left within 30')±
4WD115' ± 315' (Difference between
right and left within 30')±
Kingpin inclination2WD1500'±
4WD1450'±
Shock absorber attaching dimension mm1 ± 2±
Upper arm ball joint starting torque Nm2WD0.8 ± 3.4±
Strut bar attaching dimension mm79±
Lower arm ball joint end play mm±0.5
Lower arm bush press-fitting force kN9.8±
Clearance between bump stopper and
bump stopper bracket mm4WD21 ± 23±
Stabilizer link assembly attaching
dimension mm4WD16 ± 18±
SEALANT33200050015
ItemSpecified sealant
Upper arm ball joint dust cover <2WD>3M ATD Part No. 8661 or equivalent
Page 568 of 1310
REAR SUSPENSION ± On-vehicle Service34-3
ON-VEHICLE SERVICE34101100034
REAR WHEEL ALIGNMENT
The rear suspension assembly must be free of worn, loose
or damaged parts prior to measurement of rear wheel
alignment.
Standard value:
Toe-in 0 mm
Camber 0
NOTE
Toe-in and camber are set at the factory and cannot be
adjusted. If toe-in or camber is not within the standard value,
check and replace bent or damaged parts.
Page 571 of 1310

35A-2
BASIC BRAKE
SYSTEM
CONTENTS35109000197
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 5. . . . . . . . . . . . . . . . .
LUBRICANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 10. . . . . . . . . . . . . . . . . . . .
Brake Pedal Check and Adjustment 10. . . . . . . . . .
Stop Lamp Switch Check 11. . . . . . . . . . . . . . . . . . . . .
Brake Booster Operating Test 11. . . . . . . . . . . . . . . . .
Check Valve Operation Check 12. . . . . . . . . . . . . . .
Brake Booster Vacuum Switch Check
12. . . . . . . . . . . . . . . . . . .
Bleeding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Fluid Level Sensor Check 13. . . . . . . . . . . . . Load Sensing Spring Length Check and
Adjustment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Sensing Proportioning Valve Function
Test 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Pad Check and Replacement 15. . . . .
Front Disc Brake Rotor Check 16. . . . . . . . . . . . . . .
Brake Lining Thickness Check 17. . . . . . . . . . . . . . .
Brake Drum Inside Diameter Check 18. . . . . . . . . .
Brake Lining and Brake Drum Connection
Check 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PEDAL 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER AND BRAKE
BOOSTER 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VA LV E 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKE 24. . . . . . . . . . . . . . . . . . . . .
REAR DRUM BRAKE 30. . . . . . . . . . . . . . . . . . . . .
Page 574 of 1310

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±
Page 608 of 1310

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.