1998 MITSUBISHI MONTERO brake sensor

hardware.
Attaching hardware threads
damaged ................ A ... Require repair or replacement
of hardware.
Attaching hardware threads
stripped (threads
missing) ............... A ... Require repair or replacement
of hardware.
Code set (if
applicable) ............ A .......... (1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A .. Require repair or replacement.
Inoperative ............. B .. Require repair or replacement.
( 3) Further inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Refer to manufacturer's diagnostic trouble code procedure
and require repair or replacement of affected component(s).
( 2) - Determine cause and correct prior to repair or replacement
of part.
( 3) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable. Check
for accepted cleaning procedure.









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FLUID
See BRAKE FLUID.
FLUID LEVEL SENSOR SWITCHES
See SWITCHES.
FOUR WHEEL DRIVE SWITCHES
See SWITCHES.

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)

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.

Removal & Installation (3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
clip, brake pad retaining pins and spring. See Fig. 17. Remove shims
and pads from caliper. Keep track of location of shims for reassembly.
2) Compress caliper pistons fully in bores. Install shims on
brake pads. Install brake pads. Install spring clip, pad retaining
pins and clip. Start engine and depress brake pedal several times to
expand caliper piston. Check brake fluid level.
FRONT BRAKE CALIPER
Removal
Raise and support vehicle. Remove front wheels. Remove hose
clip from brake hose mount (if equipped). Disconnect brake hose from
caliper. Remove upper and lower caliper-to-steering knuckle bolts.
Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Bleed brake system. See
BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal & Installation (Except Montero & Montero Sport)
Raise vehicle, and remove wheel(s). Remove caliper. See
FRONT BRAKE CALIPER . Slide rotor off hub. To install, reverse removal
procedure.
Removal (Montero & Montero Sport)
Raise and support vehicle. Remove brake caliper. See
FRONT BRAKE CALIPER . On 4WD, remove Remove bearing grease cap, snap
ring, shim, 6 bolts and drive flange from axle shaft. On 2WD remove 6
bolts and hub cover. Remove screw(s) from lock washer. Remove lock
washer. Remove lock nut using Lock Nut Wrench (MB990954). Remove hub
assembly. Place match marks on rotor and hub. Remove rotor from front
hub.
Installation
1) Install rotor on hub. Service wheel bearings and seals as
necessary. Install front hub assembly. Install lock nut, and tighten
it to 119 ft. lbs. (165 N.m). Loosen lock nut, and retighten it to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Install lock washer
and screw(s).
2) On 2WD, reverse removal procedure for remaining
components. On 4WD, install drive flange, shim and snap ring. Using
feeler gauge, check axle shaft-to-hub clearance. Clearance should be
0.016-0.028" (0.41-0.71 mm). Use appropriate shim to obtain correct
clearance. Shim is located behind snap ring on end of axle shaft.
Recheck clearance if necessary. Install remaining components.
PARKING BRAKE SHOES
Removal & Installation (Diamante)
1) Raise and support vehicle. Remove rear wheels. Remove rear
disc brake caliper and rotor. If rotor removal is difficult, rotate
rotor until hole in rotor is upward. Back-off brake shoe adjustment
with a flat blade screwdriver through hole in rotor.
2) Disconnect rear speed sensor. See Fig. 9. Remove 4 bolts
and hub. Remove screw and shoe hold-down spring. Remove shoe. To
install, reverse removal procedure. Adjust brake shoe by turning
adjuster star wheel.

Removal (Eclipse, Montero & Montero Sport)
1) Raise and support vehicle. Remove rear wheels. Disconnect
rear speed sensor (if equipped). Remove rear disc brake calipers and
rotors. See REAR BRAKE CALIPER .
2) Remove adjuster spring. Remove shoe hold-down cup, spring
and pin. See Fig. 10. Note how shoe-to-anchor spring is installed, and
then remove adjuster and shoe-to-anchor spring. Remove strut and
return spring. Remove clip and shoe and lining assembly.
Fig. 9: Exploded View Of Parking Brake Assembly (Diamante)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 10: Exploded View Of Parking Brake Assembly (Typical With Rear
Disc Brakes - Except Diamante)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Shoe-to-anchor spring must be installed correctly for proper
functioning of parking brakes.
Installation
1) To install, reverse removal procedure. When installing
shoe-to-anchor spring, ensure spring is installed correctly. When
installing adjuster, install left adjuster with adjusting bolt facing
vehicle front and right adjuster with adjusting bolt facing vehicle
rear.
2) On models with ABS, ensure gap between rotor teeth and
speed sensor pole piece is 0.008-0.039" (0.20-1.00 mm).
Removal (3000GT)
1) Raise and support vehicle. Remove rear wheel(s).
Disconnect rear speed sensor. Remove rear disc brake calipers and

WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES . Remove wheel cylinder and seal assembly.
To install, reverse removal procedure. Bleed brakes. See
BLEEDING BRAKE SYSTEM .
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 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. See MASTER CYLINDER PUSH ROD under ADJUSTMENTS.
After installation, adjust pedal height. See BRAKE PEDAL HEIGHT & FREE
PLAY under ADJUSTMENTS. Bleed brake system.
POWER BRAKE BOOSTER
Removal
Remove brake master cylinder. See MASTER CYLINDER. Disconnect
vacuum hose from power brake booster. Disconnect clevis pin attaching
brake pedal to power brake booster push rod. From inside vehicle,
remove 4 nuts attaching power brake booster to firewall. Remove power
brake booster.
Installation
To install, reverse removal procedure. Install master
cylinder. Bleed brake system if necessary.
POWER BRAKE BOOSTER CHECK VALVE
NOTE: To test check valve before removal, see POWER BRAKE BOOSTER
under TESTING.
Removal & Installation
Remove vacuum hose with check valve from power brake booster.
Loosen hose clamp(s) and remove check valve from hose on Mirage and
Summit. On all models, coat end(s) of check valve with sealant before
installation. Install valve with arrow (identification mark) pointing
toward intake manifold. Install and secure hose clamp(s).
REAR AXLE BEARINGS & OIL SEAL
Removal (Montero & Montero Sport)
1) With disc or drum removed, disconnect brake line from
caliper or wheel 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
and puller to remove.
2) Remove shims, "O" ring and snap ring. Retain shims for
installation. 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

cavity and contact surfaces. Install oil seal using seal driver. Press
new oil seal into bearing case until it is flush with face of bearing
case. Install backing plate and bearing case.
2) Apply grease to external surfaces of bearing outer race.
Press bearing outer race into bearing case. Install rear brake
assembly and bearing case. Pack bearing case and axle threads with
grease. Install new retainer ring and snap ring.
3) Using a feeler gauge, measure clearance between snap ring
and new retainer ring. Clearance should be less than 0.0065" (0.165
mm). If clearance exceeds specification, install a new selective snap
ring to bring clearance to specification. See SNAP RING THICKNESS
SPECIFICATION table.
SNAP RING THICKNESS SPECIFICATION









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Thickness: In. (mm) Color\
0.060 (1.52) ................................................... Red\
0.067 (1.70) ................................................ Purple\
0.073 (1.85) .................................................. Blue\
0.079 (2.01) ................................................ Yellow\
0.085 (2.16) ............................................... Neutral\









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4) Check condition of oil seal and replace as necessary.
Install axle shaft assembly into axle housing. Tighten bearing
retainer bolts to 65 ft. lbs (15 N.m.). To complete installation,
reverse removal procedure.
REAR AXLE HUB BEARINGS
NOTE: Rear hub bearings are not serviceable on FWD models.
Removal & Installation (FWD Models)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). On models with drum brakes, remove brake
drum and shoes. See REAR BRAKE DRUM & SHOES .
2) On models with disc brakes, remove caliper and rotor. On
all models, remove hub bolts or spindle nut and hub assembly. To
install, reverse removal procedure. Tighten hub bolts or spindle nut
to specification. See HUB TIGHTENING TORQUE table. Rotate brake drum
or disc to ensure free movement.
NOTE: Rear hub bearings are not serviceable on Eclipse AWD models.
Removal & Installation (Eclipse AWD)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). On models with drum brakes, remove brake
drum and shoes. See REAR BRAKE DRUM & SHOES .
2) On models with disc brakes, remove caliper and rotor. On
all models, remove axle nut. Remove 4 hub bolts and hub assembly. To
install, reverse removal procedure. Tighten hub bolts to
specification. See HUB TIGHTENING TORQUE table. Rotate brake drum or
disc to ensure free movement.
HUB TIGHTENING TORQUE









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Application Ft. Lbs. (N.m)\
Hub Mounting Bolts ................................... 54-65 (74-85)\
Spindle Nut
Mirage ................................................. 127 (172)\
3000GT FWD ............................................. 170 (230)\