2005 MITSUBISHI 380 Workshop Manual

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-28
2. If the protrusion amount is not within the standard value
range, adjust the push rod length by turning the push rod.
Use special tool MB991568 to turn the push rod while
holding the rod spline with angle-nose pliers.
MASTER CYLINDERM1351004200375
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY STEPS
1. BRAKE MASTER CYLINDER TO
FLUID RESERVOIR SEAL
2. BRAKE MASTER CYLINDER PIN
<>3. BRAKE MASTER CYLINDER UNION
RETAINER
4. PRIMARY PISTON ASSEMBLY
5. SECONDARY PISTON ASSEMBLY
6. MASTER CYLINDER BODYDISASSEMBLY STEPS

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-29
DISASSEMBLY SERVICE POINT
.
<> BRAKE MASTER CYLINDER UNION
RETAINER DISASSEMBLY
Remove the brake master cylinder union retainer while
depressing the piston.
INSPECTIONM1351004300297
Check the inner surface of master cylinder body for rust or
pitting.
Check the primary and secondary pistons for rust, scoring,
wear or damage.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-30
DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATIONM1351008000050
Required Special Tool:
MB990520: Disc Brake Piston Expander
Pre-removal Operation
Brake Fluid DrainingPost-installation OperationBrake Fluid Supplying and Air Bleeding (Refer to
P.35A-16).
REMOVAL STEPS
BRAKE FLUID DRAINING
1. BRAKE HOSE CONNECTION
2. GASKET
3. BRAKE CALIPER ASSEMBLY
4. BRAKE DISC
INSTALLATION STEPS
BRAKE FLUID DRAINING
4. BRAKE DISC
3. BRAKE CALIPER ASSEMBLY
2. GASKET1. BRAKE HOSE CONNECTION
BRAKE FLUID SUPPLYING AND AIR
BLEEDING (Refer to P.35A-16.)
>>A<

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-31
INSTALLATION SERVICE POINT
.
>>A<< BRAKE DRAG FORCE CHECK
1. In order to measure the brake drag force, measure the hub
torque with the pads removed by the following procedure.
Use a spring scale to measure the hub torque in the forward
direction. Record hub torque with pads removed.
Do not let any oil, grease or other contamination get onto
the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool
MB990520.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and installing the lock
pin bolt.
5. Check the brake drag force as follows.
(1) Start the engine and hold the brake pedal down for 5
seconds. [Pedal depression force: approximately 200 N
(45 pound)]
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-32
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value:
3.8L engine> 64 N (14 pounds) or less
54 N (12 pounds) or less
6. If the brake drag force exceeds the standard value,
disassemble and clean the piston. Check for corrosion or
worn piston seal, and check the sliding condition of the lock
pin and guide pin.
INSPECTIONM1351008100046.
BRAKE DISC CHECK
Disc wear (Refer to P.35A-19).
Disc run-out (Refer to P.35A-19).

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-33
DISASSEMBLY AND ASSEMBLY M1351008200065
DISASSEMBLY STEPS
1. PAD & SHIM ASSEMBLY
2. CLIP
3. N/A
4. GUIDE PIN BOLT
5. CALIPER BODY
6. GUIDE PIN7. BOOT
8. CALIPER SUPPORT
<>9. CALIPER PISTON
<>10. PISTON BOOT
<>11. PISTON SEALDISASSEMBLY STEPS (Continued)