2005 MITSUBISHI 380 service

ON-VEHICLE SERVICE
BASIC BRAKE SYSTEM35A-23
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.
5. If the run-out cannot be corrected by changing the phase of
the brake disc, replace the brake disc or grind it with the
on-the-car type brake lathe ("MAD, DL-8700PF" or
equivalent).
MASTER CYLINDER FUNCTION CHECKM1351010200266
1. Remove the reservoir cap.
2. While watching the open reservoir from a distance of 50 cm
(20 inches), have an assistant depress the brake pedal. If
there was a stream of brake fluid rising from the reservoir,
proceed to Step 3. If there was no stream of brake fluid
rising from the reservoir, repair or replace the master
cylinder.
3. While watching the open reservoir from a distance of 50 cm
(20 inches), have the assistant release the brake pedal. If
there was a small amount of air bubbles rising through the
brake fluid, master cylinder function is normal. If there were
no bubbles rising through the brake fluid, repair or replace
the master cylinder.

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
BASIC BRAKE SYSTEM35A-27
INSTALLATION SERVICE POINTS
.
>>A<< BRAKE BOOSTER VACUUM HOSE
CONNECTION
Insert vacuum hose with its paint mark facing upward.
.
>>B<< PUSH ROD PROTRUSION AMOUNT
CHECK AND ADJUSTMENT
1. Use the vacuum pump to measure dimension "A" applying a
negative pressure of 66.7 kPa (19.7 inHg) to the brake
booster.
Standard value (A): 5.0 mm
0.1

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-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-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.
.

DISC BRAKE ASSEMBLY
BASIC BRAKE SYSTEM35A-38
<> PISTON BOOT/CALIPER PISTON
REMOVAL
Blow air little by little to remove the piston. The piston will
pop out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown.
Blow compressed air through the brake hose connection hole
to remove the piston boot and piston.
.
<> PISTON SEAL REMOVAL
Do not use a flat-tipped screwdriver or similar tool to
remove piston seal. These may damage the inner side of
the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean piston surface and inner cylinder with alcohol or brake
fluid DOT 3 or DOT 4.
ASSEMBLY SERVICE POINT
.
>>A<< REAR BRAKE PIN INSTALLATION
Attach a guide pin (with "g" on the bolt head) at the bleeder nip-
ple side of the caliper body and a lock pin (with "l" on the bolt
head) at the opposite side.
INSPECTIONM1351008300039
Check the cylinder for wear, damage or rust.
Check the piston surface for wear, damage or rust.
Check the caliper body or sleeve for wear.
Check the pad for damage or adhesion of grease, check the
backing metal for damage.
.