2005 MITSUBISHI 380 Workshop Manual

CLUTCH CONTROL
CLUTCH21A-6
INSTALLATION SERVICE POINT
<> CLUTCH HOSE INSTALLATION
Holding the nut at the clutch hose side, loosen the
flare nut of the clutch pipe.
>>A<< CLUTCH HOSE/CLUTCH PIPE
INSTALLATION
1. Temporarily tighten the clutch pipe flare nut by
hand, and then tighten it to the specified torque,
being careful that the clutch hose does not become
twisted.
2. After tightening the clutch pipe flare nut and eye
bolt, check to be sure there is no clutch fluid leak
INSPECTION
M1211002000158
Check the master cylinder or clutch hose for fluid
leakage.
Check the clutch hose or tube for cracks or
clogging.
Check the pedal shaft bushing for wear.
Check the pedal arm for bend or torsion.

CLUTCH CONTROL
CLUTCH21A-7
DISASSEMBLY AND REASSEMBLY
M1211002100230
CLUTCH MASTER CYLINDER
Do not disassemble the piston assembly.
Disassembly steps
1. Piston stopper ring
2. Piston assembly
>>A<<3. Pushrod assembly
4. Boot5. Spring pin
6. Nipple
7. Seal
8. Master cylinder bodyDisassembly steps (Continued)

CLUTCH CONTROL
CLUTCH21A-8
REASSEMBLY SERVICE POINT
>>A<< PUSHROD ASSEMBLY
INSTALLATIONSet the length of the pushrod assembly to the
dimension shown to make the adjustment of the
clutch pedal easier.
INSPECTIONM1211002200152
Check inside the cylinder body for rust and scars.
Check the piston for rust and scars.
Check the pipe connection for clogging.

35-1
GROUP 35
SERVICE BRAKES
CONTENTS
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35A
ANTI-LOCK BRAKING SYSTEM (ABS). . . . . . . . . . . . . . . . . . .35B

NOTES

35A-1
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .35A-2
BASIC BRAKE SYSTEM DIAGNOSIS35A-3
INTRODUCTION TO BASIC BRAKE
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . 35A-3
BASIC BRAKE SYSTEM DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . . . 35A-3
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35A-3
SYMPTOM PROCEDURES . . . . . . . . . . . . 35A-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .35A-12
ON-VEHICLE SERVICE . . . . . . . . . . .35A-13
BRAKE PEDAL CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 35A-13
BRAKE BOOSTER OPERATING TEST . . . 35A-14
CHECK VALVE OPERATION CHECK . . . . 35A-15
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-16
BRAKE FLUID LEVEL SENSOR CHECK. . 35A-17
DISC BRAKE PAD CHECK AND
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-17
DISC BRAKE ROTOR CHECK . . . . . . . . . . 35A-19
MASTER CYLINDER FUNCTION CHECK . 35A-23
BRAKE PEDAL. . . . . . . . . . . . . . . . . .35A-24
REMOVAL AND INSTALLATION . . . . . . . . 35A-24
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-25
MASTER CYLINDER ASSEMBLY
AND BRAKE BOOSTER . . . . . . . . . .35A-26
REMOVAL AND INSTALLATION . . . . . . . . 35A-26
MASTER CYLINDER . . . . . . . . . . . . . . . . . 35A-28
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-29
DISC BRAKE ASSEMBLY . . . . . . . . .35A-30
REMOVAL AND INSTALLATION . . . . . . . . 35A-30
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-32
DISASSEMBLY AND ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . 35A-33
DISASSEMBLY AND ASSEMBLY 35A-36
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-38
SPECIFICATIONS . . . . . . . . . . . . . . .35A-40
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 35A-40
GENERAL SPECIFICATIONS . . . . . . . . . . 35A-40
SERVICE SPECIFICATIONS . . . . . . . . . . . 35A-41
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 35A-41

GENERAL DESCRIPTION
BASIC BRAKE SYSTEM35A-2
GENERAL DESCRIPTIONM1351000100440
The brake system has been designed to give greater
reliability and durability and to provide excellent brak-
ing performance.
FEATURES
.
Improved braking performance
1. An 8+9 inch tandem brake booster provides suffi-
cient braking force in sudden braking range.
2. 296mm front ventilated disc brakes provide sta-
ble braking force and improved braking feel.
3. 303mm rear ventillated disc brakes are used.
.
Improved stability
1. A 4-wheel anti-lock braking system (4ABS) pre-
vents slipping caused by the vehicle wheels lock-
ing up, in order to maintain a stable vehicle
posture and steering performance.
2. An electronic brake-force distribution (EBD)
makes it possible to maintain the maximum
amount of braking force even when the vehicle's
load is unevenly distributed. 3. Front- and rear-wheel X-type brake line layout
are used.
4. Ventilated discs brakes improve anti-fading per-
formance.
.
Improved serviceability
1. A diagnosis function for the ABS system makes
inspection easier.
2. An outer disc separated hub and rotor make
removal and installation easier.
3. The master cylinder reservoir is utilised for both
brake and clutch fluid on manual transmission
vehicles.
4. The master cylinder filter is coloured black for
improved viewing.
5. The ABS-ECU and hydraulic unit are integrated
to make them more compact and light weight.
CONSTRUCTION DIAGRAM

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-3
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSISM1351009700319
Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disc brakes. Mal-
functions such as insufficient braking power or the
generation of noise may occur due to wear, damage
or incorrect adjustment of these components.
BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGYM1351009800316
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
basic brake system fault.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the symptom
chart.
4. Verify malfunction is eliminated.
SYMPTOM CHARTM1351009900324
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
.DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad
contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES :
Replace the part and determine the
source/cause of foreign material. Then go to
St e p 5.
NO : Go to Step 2. SYMPTOM INSPECTION
PROCEDUREREFERENCE
PA G E
Vehicle pulls to one side when brakes are applied 1
P.35A-3
Insufficient braking power 2
P.35A-4
Increased pedal stroke (Reduced pedal-to-floor board clearance)3
P.35A-5
Brake drag 4
P.35A-6
Scraping or grinding noise when brake are applied 5
P.35A-7
Squealing, groaning or chattering noise when brake are applied 6
P.35A-8
Squealing noise when brakes are not applied 7
P.35A-9
Groaning, clicking or rattling noise when brakes are not applied8
P.35A-11