2000 MITSUBISHI MONTERO Service Repair Manual

BASIC BRAKE SYSTEM
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35A-2
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 5.................
LUBRICANTS 6..............................
SPECIAL TOOLS 6..........................
TROUBLESHOOTING
7......................
ON-VEHICLE SERVICE 19...................
Brake Pedal Check and Adjustment 19..........
Hydraulic Brake Booster (HBB) Operation Check
20........................
HBB Check 23............
HBB Motor Relay Continuity Check
24........................
Brake Booster Operating Test
24.....................
Check Valve Operation Check
25.....................
Load Sensing Spring Length Check and
Adjustment 25.........
Load Sensing Proportioning Valve Function
Test 26................
Bleeding 27...............Bleeding 29.............
Brake Fluid Level Sensor Check 30.............
Brake Booster Vacuum Switch Check
30..................
Disc Brake Pad Check and Replacement 31.....
Disc Brake Rotor Check 32.....................
Brake Disc Thickness Check 32.................
Brake Disc Run-out Check and Correction 33....
BRAKE PEDAL 34..........................
HYDRAULIC BRAKE BOOSTER (HBB)
36....................
HBB BUZZER 40......
MASTER CYLINDER AND BRAKE
BOOSTER 41......
Master Cylinder 43.............................
FRONT DISC BRAKE 44....................
REAR DISC BRAKE 49......................
LOAD SENSING PROPORTIONING
VALVE 54..........


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BASIC BRAKE SYSTEM -General Information35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
ItemsSpecifications
Hydraulic brake boosterMaster cylinder typeSingle type (with center valve)
(HBB) Master cylinder I.D. mm22.22
Boosting ratio5.4
Master cylinderTypeTandem type
I.D. mm23.81
Brake boosterTypeVacuum type, tandem
Effective dia. of power cylinder mm216 + 217
Boosting ratio6.5
Rear wheel hydraulic pressure control type Electronic brake-force distribution (EBD)
Load sensing proportioning
valveDecompression ratio0.3
Front brakesTypeFloating caliper, 2 piston, ventilated disc
Disc effective dia.¢
thickness mm241¢
26
Wheel cylinder I.D. mm45.4
Pad thickness mm10.0
Clearance adjustmentAutomatic
Rear brakesTypeFloating caliper, 1 piston, ventilated disc
Disc effective dia.¢
thickness mm256¢
22
Wheel cylinder I.D. mm44.5
Pad thickness mm10.0
Clearance adjustmentAutomatic
Brake fluidDOT3 or DOT4


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BASIC BRAKE SYSTEM -Service Specifications35A-5
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Brake pedal heightL.H. drive vehicles192 - 195-
mm
R.H. drive vehicles187 - 190-
Brake pedal play mm3-8-
Brake pedal to floorboard clearance when the brake pedal is depressed mm90 or more-
Hydraulic brake
booster (HBB)Pump motor
operation timeWhen power supply system brake fluid
pressure is not applied20 - 80-
second
When power supply system brake fluid
pressure is applied2-11-
Hydraulic pressurePedal depressionFront0.6 or more-
during no vacuum
operation testforce: 100 N
Rear0-
MPa
Pedal depressionFront4.5 or more-
force: 500 N
Rear0-
Hydraulic pressurePedal depressionFront3.0 - 4.0-
during vacuum op-
eration test
MPa
force: 100 N
Rear3.3 - 4.3-
Pedal depressionFront8.0 - 10.0-
force: 200 N
Rear8.0 - 10.0-
Pedal depressionFront14.0 - 18.0-
force: 400 N
Rear14.0 - 18.0-
Pedal depressionFront15.0 - 19.0-
force: 500 N
Rear15.0 - 19.0-
Clearance between brake booster push rod and primary piston6G70.5 - 0.9-
mm
4D5, 4M40.8 - 1.2-
Load sensing propor-When load sensing spring length is 133Short wheelbase4.9 - 5.9 (9.8)-
tioning valve output
fluid pressure (Inputmm (when unladen)
Long wheelbase5.9 - 6.9 (9.8)-
fluid pressure) MPa
ABS>mm (when laden)
9.0 - 11.0
(16.7)-
Long wheelbase9.3 - 10.3 (9.8)-
11.4 - 13.4
(16.7)-
Load sensing spring length mm
135 - 139-


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F
ro nt dis c bra ke P
ad th ic kn ess mm 1
0.0 2
.0 D
is c th ic kn ess mm 2
6.0 2
4.4 D
is c ru nout mm - 0
.0 6 D
ra g fo rc e N 5
5 -
R
ear dis c bra ke P
ad th ic kn ess mm 1
0.0 2
.0 D
is c th ic kn ess mm 2
2.0 2
0.4 D
is c ru nout mm - 0
.0 6 D
ra g fo rc e N 5
5 -
F
ro nt hub end pla y mm - 0
R
ear hub end pla y mm - 0
S
pecif ie d Lubric a nt Q
uantit y B
ra ke flu id D
O T3 or D O T4 A
s re quir e d P
is to n boot, pis to n se al R
epair kit gre ase G
uid e pin ,lo ck pin P
is to n, w heelcylin der body D
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um ber N
am e U
se M
B991502 M
UT-II su b
a sse m bly M
B991529 D
ia gnosis co de
c h eck harn ess M
B991620 V
alv e sp rin g
c o m pre sso r adapte r H
old in g hyd ra ulic bra ke booste r (H BB)

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B991568 P
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s o cke t A
dju stm ent of th e bra ke booste r push ro d
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ra ke to ols e t
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ra ke warn in g la m p
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