2005 MITSUBISHI 380 service

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-15
(2) With the engine stopped, step on the brake pedal several
times. Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.
(3) With the engine running, step on the brake pedal and
then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster
is in good condition, if the pedal rises, the booster is
defective.
2. If the above three tests are okay, the booster is OK. If one of
the above three tests is not okay, the check valve, vacuum
hose, or booster is defective. Check the check valve (Refer
to P.35A-15), vacuum hose for leaks, high volume engine
vacuum applied to booster. Repair or replace as necessary.
If these are OK, replace booster and repeat this test starting
at Step 1.
CHECK VALVE OPERATION CHECKM1351009000376
The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to P.35A-26).
If the check valve is defective, replace it as an assembly
together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum
pump.
VACUUM PUMP
CONNECTIONCRITERIA
Connection at the brake
booster side (A)A negative pressure
(vacuum) is created and
held.
Connection at the intake
manifold side (B)A negative pressure
(vacuum) is not created.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-16
BLEEDINGM1351001400455
Use only brake fluid DOT 3 or DOT 4. Never mix the speci-
fied brake fluid with other fluid as it will influence the brak-
ing performance significantly.
.
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if bleeding is
carried out by the following procedure, bleeding of air from the
brake pipeline will become easier. (When brake fluid is not con-
tained in the master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a
finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2
4 three or four times to fill the inside of the
master cylinder with brake fluid.
.
BRAKE LINE BLEEDING
Start the engine and bleed the air in the sequence shown in the
figure.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-17
BRAKE FLUID LEVEL SENSOR CHECKM1351009100403
The brake fluid level sensor is in good condition if there is no
continuity when the float surface is above "MIN" and if there is
continuity when the float surface is below "MIN".
DISC BRAKE PAD CHECK AND REPLACEMENTM1351002300398
NOTE: Uneven wearor tapering of brake pad may be caused
by either caliper piston not operating correctly .
Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.
If there is a significant difference in the thicknesses of
the pads on the left and right sides, check the sliding
condition of the piston and slide pins.
1. Check the brake pad thickness through the caliper body
check port.(Rear). Front pad check can be viewed from rotor
side.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-18
Do not wipe off the special grease that is on the lock pin.
Do not contaminate the lock pin.
2. Remove the lock pin bolt . Pivot the caliper assembly
upward and secure. Hold lock pin with spanner while
loosening bolt(Rear).

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.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-20
.
BRAKE DISC THICKNESS CHECK
1. Using a micrometer, measure disc thickness at eight
positions, approximately 45 degrees apart and 10 mm (0.4
inch) in from the outer edge of the disc.
FRONT BRAKE DISC
Standard value: 26.0 mm (1.02 inches)
Minimum limit: 24.4 mm (0.96 inch)
REAR BRAKE DISC
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 8.4 mm (0.33 inch)
NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch). INSPECTION ITEM REMARK
Scratches, rust, saturated lining materials and wear
If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing
will cause warping or distortion.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-21
After a new brake disc is installed, always grind the
brake disc with an on-the-car type brake lathe. If this
step is not carried out, the brake disc run-out exceeds
the specified value, resulting in judder.
When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inac-
curate grinding.
Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N
m (74
ft-lb). If all of the wheel nuts are not used, or the tight-
ening torque is excessive or not equal, the brake disc
rotor or drum may be deformed, resulting in judder.
2. If the disc thickness is less than the limit, replace it with a
new one. If thickness variation exceeds the specification,
turn rotor with an on-the-car type brake lathe
("Accuturn-8750" or equivalent). If the calculated final
thickness after turning the rotor is less than the standard
value, replace the disc.
.

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-22
BRAKE DISC RUN-OUT CHECK AND
CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm (0.2 inch) from the
outer circumference of the brake disc, and measure the
run-out of the disc.
Limit:
: 0.10 mm (0.0039 inch)
: 0.04 mm (0.0016 inch)
4. If the brake disc run-out exceeds the limit, correct it as
follows:
(1) Chalk phase marks on the wheel stud and the brake disc
as shown.
(2) Remove the brake disc. Then 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)
(3) If the end play exceeds the limit, replace the hub
assembly.
(4) If the end play does not exceed the limit, dephase the
brake disc and secure it. Then recheck the brake disc
run-out.