1998 MITSUBISHI MONTERO Service Manual

BRAKE SYSTEM
1998 Mitsubishi Montero
1997-98 BRAKES
Mitsubishi - Disc & Drum
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
INTRODUCTION
This article contains information on repair and service of
basic hydraulic brake system. If vehicle is equipped with anti-lock
brakes, also see appropriate ANTI-LOCK article.
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake booster, proportioning valve and self-adjusting assembly.
Montero has a Load-Sensing Proportioning Valve (LSPV). All models are
equipped with front disc brakes and either rear disc or drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Bleed brakes whenever hydraulic lines are opened or pedal
feels spongy. Bleed system in appropriate sequence. See
BRAKE LINE BLEEDING SEQUENCE table. Use only DOT 3 or DOT 4 approved
fluid and DO NOT mix fluid types.
BRAKE LINE BLEEDING SEQUENCE









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Application Sequence
Diamante, Eclipse, Galant,
Mirage & 3000GT .................................... RR, LF, LR, RF
Montero ....................................... RR, LR, LSPV, RF, LF
Montero Sport ....................................... RR, LR, RF, LF









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ADJUSTMENTS
BRAKE PEDAL HEIGHT, FREE PLAY & CLEARANCE
1) To measure brake pedal height, pull up carpet under brake
pedal. Measure distance between floor board and middle of brake pedal
pad surface with brake pedal released. See BRAKE PEDAL HEIGHT
SPECIFICATIONS table.
2) To adjust pedal height, separate connector from stoplight
switch, and loosen switch lock nut. Back-off switch so it does not
contact brake pedal arm. Loosen master cylinder push rod lock nut.
Adjust brake pedal height by rotating master cylinder push rod until
brake pedal height is within specification.
BRAKE PEDAL HEIGHT SPECIFICATIONS









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Application Pedal Height: In. (mm)\

Diamante, Eclipse,
Montero Sport & Galant .......................... 6.9-7.1 (175-181)\
Mirage ........................................... 6.4-6.6 (164-167)\
Montero .......................................... 7.3-7.5 (186-191)\
3000GT ........................................... 7.0-7.2 (177-182)\









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3) 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.
4) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. Free play distance for all models is
0.10-0.31" (3-8 mm). If distance is not within specification, it is
probably caused by excessive play between the brake pedal arm and the
clevis pin. Check and replace as necessary.
5) Start engine and apply 110 lbs. (490 N) of pressure to
brake pedal. With the carpet pulled back, measure the distance between
the brake pedal and the floorboard. If the distance is not 3.1-3.5"
(80-90 mm) check for air in brake hydraulic system, brake adjustment
or defective parking brake component or adjustment. Adjust or repair
as necessary.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Park vehicle on level surface. Remove excess weight from
vehicle. Make sure the lever is all the way towards the valve side.
Measure length of entire spring. See Fig. 1.
If spring length is not within specification, adjust spring
support until correct length is obtained. See LSPV SPRING LENGTH
table.
Fig. 1: Adjusting Load-Sensing Proportioning Valve Spring (Montero)
Courtesy of Mitsubishi Motor Sales of America.
BRAKE BOOSTER PUSH ROD

Adjustment (Except Diamante)
1) Place the Push Rod Adjusting Gauge (MB991714) in the
master cylinder, position gauge shaft so it contacts master cylinder
piston and tighten wing bolt.
2) Apply a vacuum of 9.7 psi (-66.7 kPa) for Eclipse, Galant\
,
Montero and 3000GT and 19.6 psi (-66.7 kPa) for Mirage and Montero
Sport to the brake booster using a hand held vacuum pump.
3) Rotate the gauge tool so it is positioned offset from
center of the brake booster. See Fig. 2.
Fig. 2: Push Rod Adjusting Gauge Setup.
Courtesy of Mitshbishi Motor Sales of America.
4) Move the gauge tool towards the center so the shaft
contacts the end of the brake booster push rod. If contact is not as
shown in position "A", shorten the rod if position "B" is present, or
lengthening it if position "C" is present. See Fig. 3.

Fig. 3: Adjusting Brake Booster Push Rod Clearance
Courtesy of Mitshbishi Motor Sales of America.
Adjustment (Diamante)
1) Start engine and depress the brake pedal at least two

times then switch the engine off.
2) Remove the master cylinder from the brake booster making
sure the push rod is not disturbed and the brake pedal is not
depressed after master cylinder removal.
3) Using a Vernier Caliper and Block Gauge, measure the
thickness of the block gauge and add .366" (9.3 mm) to the gauge
thickness and set the caliper to this dimension. See Fig. 4.
Fig. 4: Setting Caliper And Block Gauge (Diamante)
Courtesy of Mitshbishi Motor Sales of America.
4) Check the push rod position with vernier caliper set to
the calculated dimension. Specification range .362"-.370" (9.2-9.4
mm). See Fig. 5.

Fig. 5: Push Rod Setting (Diamante)
Courtesy of Mitshbishi Motor Sales of America.
5) If clearance is NOT within range, turn push rod screw to
correct length.
NOTE: This measurement is taken on the radial face of the push
rod, .085" (2.15 mm) from the center of the radial face.
This adjusting procedure MUST be done with 18-22 in. Hg

(62-73 kPa) of vacuum applied to the brake booster.
PARKING/EMERGENCY BRAKE
NOTE: Adjust service brakes before adjusting parking brake.
Start engine, and apply brake pedal. Pull parking brake lever
with a force of 44-45 lbs. (196-200 N). Parking brake lever should
move up 3-5 notches on Diamante, Stealth and 3000GT, 4-6 notches on
Montero, and 5-7 notches on all other models. If adjustment is
necessary, turn adjusting nut located under console or at end of cable
rod. See Fig. 6.
Fig. 6: Adjusting Parking/Emergency Brake (Typical)
Courtesy of Mitsubishi Motor Sales of America.
REAR BRAKE SHOES
Fully release parking brake and depress brake pedal several
times to center shoes and adjust brake shoe clearance. Adjust shoes so
brake shoes lightly contact brake drum. Adjust parking brake, and
check pedal travel. Rotate brake drum to verify free movement.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
0.02-0.04" (0.5-1.0 mm). Tighten lock nut. DO NOT depress master
cylinder push rod during stoplight switch adjustment.
TESTING