2005 MITSUBISHI 380 Workshop Manual

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-4
STEP 2. Check disc brake pistons for smooth
operation.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserves.
(2) Test each disc brake assembly one at a time.
a. Remove the lower caliper bolt, then remove
caliper from mount.
b. Have an assistant slowly depress the brake
pedal. Confirm piston(s) extend slowly and
smoothly with no jumpiness. Repeat for each
disc brake assembly.
Q: Do (does) the piston(s) move correctly?
YES :
Go to Step 3.
NO : Disassemble and inspect the brake
assembly (Front: refer to P.35A-33, Rear:
refer to P.35A-36). Then go to Step 5.
STEP 3. Check brake disc(s) for runout.
Refer to P.35A-19.
Q: Is runout outside of specifications?
YES :
Repair or replace the brake disc(s) as
necessary. Then go to Step 5.
NO : Go to Step 4.
STEP 4. Check brake discs for correct thickness.
Refer to P.35A-19.
Q: Is the thickness outside of specifications?
YES :
Repair or replace the brake disc(s) as
necessary. Then go to Step 5.
NO : Perform the brake line bleeding. Then go to
St e p 5.
STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 2: Insufficient Braking Power
.
DIAGNOSIS
STEP 1. Check that the specified brake fluid is
used, its level is correct, and no contamination is
found.
Q: Is there a fault?
YES :
Refill or replace with the specified brake
fluid DOT 3 or DOT 4. Bleed the brakes if
necessary (Refer to P.35A-16). Then go to
Step 7.
NO : Go to Step 2.
STEP 2. Check for spongy (not firm) brakes.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete the booster
vacuum reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES :
Bleed the brakes to remove air in the fluid
(Refer to P.35A-16). Then go to Step 7.
NO : Go to Step 3.
STEP 3. Check the brake booster function.
Refer to P.35A-14.
Q: Is there a fault?
YES :
Replace the brake booster. Then go to Step
7.
NO : Go to Step 4.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-5
STEP 4. Check for pinched or restricted brake
tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES :
Replace that complete section of brake tube
or brake hose. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for oil, water, etc., on the pad
contact surfaces 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. Recheck
symptom. Then go to Step 7.
NO : The procedure is complete. If condition
persists for vehicles without ABS, go to Step
6.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)
.
DIAGNOSIS
STEP 1. Check for spongy (not firm) brakes.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring device (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES :
Bleed the brakes to remove air in the fluid
(Refer to P.35A-16). Then go to Step 7.
NO : Go to Step 2.
STEP 2. Check the pad for wear.
Refer to P.35A-17.
Q: Is the pad thickness outside of specifications?
YES :
Replace the part. Then go to Step 7.
NO : Go to Step 3.
STEP 3. Check the vacuum hose and check valve
for damage.
Refer to P.35A-15.
Q: Is there a damage?
YES :
Replace the part. Then go to Step 7.
NO : Go to Step 4.
STEP 4. Check the master cylinder function.
Refer to P.35A-23.
Q: Is there a fault?
YES :
Repair it. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for brake fluid leaks.
Q: Is there a leak?
YES :
Check the connection for looseness,
corrosion, etc. Clean and repair as
necessary. If leaking in any tube or hose
section, replace the complete tube or hose.
Then go to Step 7 .
NO : Go to Step 6.
STEP 6. Check for excessive clearance between
the push rod and primary piston.
Refer to P.35A-26.
Q: Is the clearance outside of specifications?
YES :
Adjust the clearance. Then go to Step 7.
NO : Go to Step 7.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the symptom chart.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-6
INSPECTION PROCEDURE 4: Brake Drag
.
DIAGNOSIS
STEP 1. Check the parking brake operating lever return.
Q: Is the operation faulty?
YES : Repair it. Then go to Step 9.
NO : Go to Step 2.
STEP 2. Check the brake shoe springs for breakage.
Q: Are the brake shoe springs broken?
YES : Replace the spring. Then go to Step 9.
NO : Go to Step 3.
STEP 3. Check the amount of grease at each sliding
section.
Refer to GROUP 36, Parking Brake Lining and Drum P.36-8.
Q: Is the grease amount low?
YES : Apply grease. Then go to Step 9.
NO : Go to Step 4.
STEP 4. Check the parking brake pull amount.
Refer to GROUP 36, On-vehicle Service
Parking Brake lever
Stroke Check and Adjustment P.36-3.
Q: Is there a fault?
YES : Adjust it. Then go to Step 9.
NO : Go to Step 5.
STEP 5. Check for insufficient clearance between the push
rod and primary piston.
Refer to P.35A-26.
Q: Is there a fault?
YES : Adjust the clearance. Then go to Step 9.
NO : Go to Step 6.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-7
STEP 6. Check the master cylinder piston return spring for
damage and return port for clogging.
Refer to P.35A-28.
Q: Is there damage?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.
STEP 7. Check port for clogging.
Q: Is the port clogged?
YES : Repair it. Then go to Step 9.
NO : Go to Step 8.
STEP 8. Check disc brake pistons for sticking.
Depress the brake pedal, then release. Confirm each wheel
spins freely.
Q: Does any wheel stick?
YES : Inspect that brake assembly. Then go to Step 9.
NO : Go to Step 9.
STEP 9. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied
.
DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for
metal-to-metal condition.
Q: Is any metal-to-metal contact evident?
YES : Repair or replace the components. Then go to Step 6.
NO : Go to Step 2.
STEP 2. Check for interference between the caliper and
wheel.
Q: Is there any interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 3.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-8
STEP 3. Check for interference between the dust cover and
brake disc.
Q: Is there any interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 4.
STEP 4. Check the brake drums or discs for cracks.
Q: Are there cracks?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 5.
STEP 5. Check for bent backing plate(s).
Q: Is (Are) the backing plate(s) bent?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 6.
STEP 6. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
INSPECTION PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
.
DIAGNOSIS
STEP 1. Check the brake disc and pads for wear
or cutting.
Q: Is there wear or cutting?
YES :
Repair or replace the part. Then go to Step
4.
NO : Go to Step 2.
STEP 2. Check the calipers for rust.
Q: Is there any rust?
YES :
Remove the rust. Then go to Step 4.
NO : Go to Step 3.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-9
STEP 3. Adjust the brake pedal or brake booster
pushrod.
Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES :
Go to Step 4.
NO : Adjust the brake pedal or the brake booster
pushrod. Then go to Step 4.
STEP 4. Recheck symptom.
Q: Is the symptom eliminated?
YES :
The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the symptom chart.
INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied
DIAGNOSIS
.
STEP 1. Check whether the backing plate is bent or loose
and interfering with the drum.
Q: Is there a fault?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 2.
STEP 2. Check whether the drum is damaged due to
interference with the backing plate or shoe.
Q: Is there any damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 3.
STEP 3. Check the brake drum for wear and the shoe
spring for damage.
Q: Is there any wear or damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 4.
STEP 4. Check the brake discs for rust.
Q: Are the brake discs rusted?
YES : Remove the rust by using sand paper. If still rusted,
turn the rotors with an on-the-car brake lathe. Then go
to Step 10.
NO : Go to Step 5.
STEP 5. Check the brake pads for correct installation.
Q: Are the pads installed incorrectly?
YES : Repair the pads. Then go to Step 10.
NO : Go to Step 6.
STEP 6. Check the calipers for correct installation.
Q: Are the calipers installed incorrectly?
YES : Repair the calipers. Then go to Step 10.
NO : Go to Step 7.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-10
STEP 7. Check the wheel bearings for end play.
(1) Remove the brake discs.
(2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 10.
NO : Go to Step 8.
STEP 8. Check whether the brake booster or master
cylinder return is insufficient.
Q: Is the brake booster or master cylinder return
insufficient?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 9.
STEP 9. Adjust the brake pedal or brake booster pushrod.
Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES : Go to Step 10.
NO : Adjust the brake pedal or the brake booster pushrod.
Then go to Step 10.
STEP 10. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-11
INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.
DIAGNOSIS
.
STEP 1. Check whether foreign material has entered the
wheel covers.
Q: Is there any foreign material?
YES : Remove it. Then go to Step 5.
NO : Go to Step 2.
STEP 2. Check for looseness of the wheel nuts.
Q: Are the wheel nuts loose?
YES : Tighten to 98
10 Nm (73 7 ft-lb). Then go to Step
5 .
NO : Go to Step 3.
STEP 3. Check for looseness of the caliper installation
bolt.
Q: Is the caliper installation bolt loose?
YES : Tighten to 100
10 Nm (74 7 ft-lb) for the front
caliper. Tighten to 60
5 Nm (45 3 ft-lb) for the rear
caliper. Then go to Step 5.
NO : Go to Step 4.