1998 MITSUBISHI MONTERO parking brake

ADJUSTMENTS
* PLEASE READ FIRST *
NOTE: For adjustment information on brake pedal height, free play,
parking brake and stoplight switch, see BRAKE SYSTEM article.
WHEEL SPEED SENSOR (WSS)
NOTE: Rear WSS gap adjustment information is not available from
manufacturer.
Front WSS-To-Rotor Gap Adjustment
1) Raise and support vehicle. Remove wheel(s). Inspect senso\
r
pole piece for damage. Repair if necessary. If sensor pole piece is
okay, check WSS-to-rotor gap.
2) Using a feeler gauge, check clearance between sensor pole
and rotor tooth surface. See Fig. 1. Front WSS sensor clearance should
be .008-.390" (0.2-1.0 mm). If clearance is not as specified, loosen
sensor mounting bolt. Adjust sensor position until clearance is within
specification. Tighten sensor mounting bolt to specification. See
TORQUE SPECIFICATIONS .
Fig. 1: Checking Front WSS-To-Rotor Gap
Courtesy of Mitsubishi Motor Sales of America.
TROUBLE SHOOTING
ANTI-LOCK WARNING LIGHT
1) Turn ignition on. ANTI-LOCK warning light should come on

Disconnect electrical connector from output speed sensor. See
Fig. 15. Remove bolt and output speed sensor. To install, reverse
removal procedure.
Fig. 15: Locating Output Speed Sensor & Connector
Courtesy of Mitsubishi Motor Sales of America.
PARK/NEUTRAL POSITION (PNP) SWITCH
Removal
Switch is located on side of transmission. Remove manual
lever from control shaft on transmission. Bend up tabs on lock washer.
Remove lock nut, lock washer and seal from control shaft. Remove
retaining bolt and neutral safety switch.
Installation
1) Install switch on control shaft. Loosely install switch
retaining bolt. Install seal and lock washer. Install lock nut and
tighten to specification. See TORQUE SPECIFICATIONS.
2) Switch must be adjusted. Ensure parking brake is applied.
Temporarily install manual lever on control shaft. Place shift lever
in Neutral. Remove manual lever. Rotate switch and align reference
mark on switch with groove.
3) Hold switch in this position. Tighten retaining bolt to
specification. Bend tabs on lock washer over against lock nut. To
install remaining components, reverse removal procedure.

* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
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

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

(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