2005 MITSUBISHI 380 brakes

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.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-19
3. Remove the following parts from the caliper support.
(1) Pad assembly
(2) Clip
4. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the hub
with the pads removed (Refer to P.35A-30).
5. Install the pads and caliper assembly, and then check the
brake drag force (Refer to P.35A-30).
6. Tighten lock pin bolt. Ensure lock pin is held with spanner
while tightening lock pin bolt(Rear) to specified torque.
DISC BRAKE ROTOR CHECKM1351002900334
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following condi-
tions should be checked.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-34
LUBRICATION POINTS
DISASSEMBLY SERVICE POINTS
When disassembling the front disc brakes, disassemble
both sides (left and right wheels) as a set.
.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-37
LUBRICATION POINTS
DISASSEMBLY SERVICE POINTS
When disassembling the disc brakes, disassemble both
sides (left and right) as a set.
.

SPECIFICATIONS
BASIC BRAKE SYSTEM35A-40
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1351009600390
GENERAL SPECIFICATIONSM1351000200362
ITEM SPECIFICATION
Brake line
Brake tube flare nut 15
2 Nm
Brake pedal
Brake booster nut 14
2 Nm
Brake pedal bolt 13
2 Nm
Front disc brake
Brake hose connector bolt 30
4 Nm
Caliper bleeder 12.5
1.5 Nm
Front brake assembly mounting bolt 100
10 Nm
Front brake bolt (guide pin bolt) 36.5
1.5 Nm
Master cylinder assembly and brake booster
Brake booster nut 14
2 Nm
Brake master cylinder mounting nut 25
2 Nm
Rear disc brake
Brake hose connector bolt 30
4 Nm
Caliper bleeder 12.5
1.5 Nm
Rear brake assembly mounting bolt 60
5 Nm
Rear brake bolt (guide pin bolt) 36.5
1.5 Nm
ITEM SPECIFICATION
Master
cylinderType Tandem type
I.D. mm 25.4
Brake
boosterType Vacuum type, tandem
Effective dia. of power
cylinder mm 205 + 230
Boosting ratio 6.5
Rear wheel hydraulic control method Electronic brake-force distribution (EBD)
Front brakes Type Floating caliper, Aluminium housing, 2 piston, ventilated disc
Disc effective dia
thickness
mm 296 28.0
Wheel cylinder I.D. mm 42.0 x 2
Pad thickness mm 10.0
Clearance adjustment Automatic

SPECIFICATIONS
BASIC BRAKE SYSTEM35A-41
SERVICE SPECIFICATIONSM1351000300477
LUBRICANTSM1351000400429
Rear brakes Type Floating caliper, Aluminium housing, 1 piston, ventilated disc
Disc effective dia
thickness
mm 303 18
Wheel cylinder I.D. mm 40.5
Pad thickness mm 10.0
Clearance adjustment Automatic ITEM SPECIFICATION
ITEM STANDARD VALUE LIMIT
Brake pedal height mm A/T 168.5
171.5
M/T 169.4 172.4
Brake pedal free play mm 3
8
Brake pedal to floor board clearance mm 110 or more
Disc brake pad thickness mm 10.0 Minimum 2.0
Disc brake disc thickness
mm Front 28.0 Minimum 26.4
Rear 18.0 Minimum 16.4
Disc brake disc run-out
mm Front
0.1
Rear
0.04
Disc brake drag force N Front 64 or less
Rear 54 or less
Hub end play mm 0.05
Brake booster push rod protruding length mm.
[When applying negative pressure of 66.7 kPa to the
brake booster]5.0
0.1
ITEM SPECIFIED LUBRICANT
Brake fluid DOT3 or DOT4
Piston boot, piston seal Repair kit grease
Front brake pin, rear brake pin (guide pin)

36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .36-2
PARKING BRAKE DIAGNOSIS . . . .36-2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 36-2
TROUBLESHOOTING STRATEGY . . . . . . 36-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 36-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 36-3
ON-VEHICLE SERVICE . . . . . . . . . . .36-3
PARKING BRAKE LEVER STROKE CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 36-3
PARKING BRAKE SWITCH CHECK . . . . . 36-5
PARKING BRAKE LINING SEATING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 36-5
PARKING BRAKE LEVER . . . . . . . . .36-6
REMOVAL AND INSTALLATION . . . . . . . . 36-6
PARKING BRAKE CABLE . . . . . . . . .36-7
REMOVAL AND INSTALLATION . . . . . . . . 36-7
PARKING BRAKE LINING AND
DRUM . . . . . . . . . . . . . . . . . . . . . . . . .36-8
REMOVAL AND INSTALLATION . . . . . . . . 36-8
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 36-11
SPECIFICATIONS . . . . . . . . . . . . . . .36-12
FASTENER TIGHTENING SPECIFICATIONS36-12
SERVICE SPECIFICATIONS . . . . . . . . . . . 36-12
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 36-12

GENERAL DESCRIPTION
PARKING BRAKES36-2
GENERAL DESCRIPTIONM1361000100344
The parking brakes are a mechanical rear wheel
brake design and controlled by a lever.
CONSTRUCTION DIAGRAM
PARKING BRAKE DIAGNOSIS
INTRODUCTIONM1361003700282
If the parking brake is faulty, parking brake effort will
become insufficient. The cause may be a malfunc-
tion of parking brake parts or the parking brake pedal
being out of adjustment.
TROUBLESHOOTING STRATEGYM1361003800290
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
parking brakes 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 CHARTM1361004100302
SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE
Brake drag
Refer to GROUP 35A, Basic Brake
System Diagnosis
Symptom
Chart P.35A-6.
Insufficient parking brake function 1
P.36-3