2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

BASIC BRAKE SYSTEM -On-vehicle Service35A-15
3. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out
of the disc.
Limit: 0.03 mm or less
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, which run-out is excessive.
(2) Remove the brake disc. Then place a dial gauge
as shown, and measure the wheel bearing axial play
by pushing and pulling the wheel hub.
Limit: 0.06 mm , 0.05 mm
(3) If the wheel bearing axial play exceeds the limit,
disassemble the hub and knuckle assembly to check
each part.
(4) If the wheel bearing axial play does not exceed the
limit, dephase the brake disc and secure it. Then
recheck the brake disc run-out.
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).
Caution
(1) After a new brake disc is installed, always grind
the brake disc with 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.
(2) When the on-the-car type lathe is used, first install
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 inaccurate grinding.
(3) Grind the brake disc with all wheel nuts diagonally
and equally tightened to the specified torque 100
N·m. When all numbers of wheel nuts are not used,
or the tightening torque is excessive or not equal,
the brake disc rotor or drum may be deformed,
resulting in judder.
M12 flat washer
M12 flat washer

BASIC BRAKE SYSTEM -Brake Pedal35A-16
BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-7.)
1
2
3
64 8
7 5
12±2 N·m
14±3 N·m
Removal steps
1. Harness connector
2. Stop lamp switch
3. Adjuster
4. Pedal stopper
5. Snap pin6. Pin assembly
7. Pedal pad
"AA8. Brake pedal and pedal support
member
INSTALLATION SERVICE POINT
"AABRAKE PEDAL AND PEDAL SUPPORT MEMBER
INSTALLATION
Tighten the brake booster mounting nuts (A), and then the
brake pedal mounting bolts (B).
NOTE
The pedal support member can not be positioned correctly
if the pedal mounting bolts (B) are tightened first as the their
holes are oblong holes.
AA
BB

BASIC BRAKE SYSTEM -Brake Pedal/Proportioning Valve,
Master Cylinder and Brake Booster35A-17
INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
PROPORTIONING VALVE, MASTER CYLINDER AND BRAKE
BOOSTER
REMOVAL AND INSTALLATION
Pre-removal Operation
DAir Intake Hose and Air Cleaner Removal

DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid DrainingPost-installation Operation
DBrake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
DBrake Pedal Adjustment (Refer to P.35A-7.)
DAir Intake Hose and Air Cleaner Installation

DStrut Tower Bar Installation (Refer to GROUP 42.)
510
11 3
12 4
14
15±2N·m 15±2N·m
22±3N·m
10±2N·m
13 2
8
14±3N·m
519

9
15±2N·m
5
Proportioning valves

67
30±5N·m
9
15
16±1N·m

9
15
16±1N·m
Vacuum hose, fitting
Specified Sealant: 3M ATD
Part No.8661, 8663 or
equivalent
15
Fitting
4mm
No continuityContinuity

BASIC BRAKE SYSTEM -ProportioningValve,MasterCylinder
and Brake Booster35A-18
Master cylinder removal steps
1. Clutch hose connection
2. Brake fluid level sensor connector
3. Reservoir cap assembly
4. Brake fluid level sensor
5. Brake pipe connection
6. Proportioning valve

7. O ring
8. Master cylinder
Proportioning valve removal steps

5. Brake pipe connection
6. Proportioning valve
7. O ring
Brake booster removal steps
1. Clutch hose connection
2. Brake fluid level sensor connector5. Brake pipe connection
8. Master cylinder
"BADPush rod protrusion amount check and
adjustment
"AA9. Vacuum hose
(With built-in check valve)
10. Snap pin
11. Pin assembly
12. Clevis
DRemove A/C liquid pipe B
from the
retaining clip.(Refer to GROUP 55A
- Refrigerant Line.)
13. Brake booster
14. Sealer
Fitting removal steps
"AA9. Vacuum hose
(With built-in check valve)
15. Fitting
INSTALLATION SERVICE POINTS
"AAVACUUM HOSE CONNECTION
Insert the vacuum hose to the brake booster with its paint
mark facing upward, and then secure the hose by using the
hose clip.
"BAPUSH ROD PROTRUSION AMOUNT CHECK AND
ADJUSTMENT
1. Measure dimension (A).
Standard value (A) : 8.98 - 9.23 mm
NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 10.27 – 10.53
mm.
Block gauge Measuring distance A
A

BASIC BRAKE SYSTEM -ProportioningValve,MasterCylinder
and Brake BoosterBASIC BRAKE SYSTEM -ProportioningValve,MasterCylinder
and Brake Booster35A-19
2. If the protrusion amount is not within the standard value
range, adjust the push rod length by turning the push
rod. Use the special tool to turn the push rod while holding
the rod spline with angle-nose pliers.
MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
1
2
3838
Brake fluid: DOT3 or DOT4
77
5Master cylinder kit
4
9
6
10
9
8
9
10
Disassembly steps
1. Reservoir cap
2. Filter
3. Spring pin
4. Reservoir tank
5. Reservoir seal6. Pin
7. Piston retainer
8. Primary piston assembly
9. Secondary piston assembly
10. Master cylinder body
Angle-nose pliers
MB991568
Rod spline

BASIC BRAKE SYSTEM -Disc Brake35A-20
DISC BRAKE
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched. And if there is
brake fluid on the caliper, wipe out quickly.
Pre-removal Operation
Brake Fluid DrainingPost-installation Operation
Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
34
21
100±10 N·m
108±10 N·m
30±5 N·m
3 2 1
54±5 N·m
15±2 N·m


4
Removal steps
1. Brake hose connection
2. Gasket
"AA3. Disc brake assembly
4. Brake disc

BASIC BRAKE SYSTEM -Disc Brake35A-21
INSTALLATION SERVICE POINT
"AADISC BRAKE ASSEMBLY INSTALLATION

1. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
(1) Withdraw the drive shaft. (Refer to GROUP 26, 27.)
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
Tightening torque:
245±29 N·m , 225±25 N·m
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
2. Install the caliper support to the knuckle, and then
assemble the pad and the clip to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
7. Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value:
51 N or less , 69 N or less
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the slide pins slide
smoothly.

1. Find the drag force of the disc brake. (Refer to P.35A-13.)
Standard value: 69 N or less
2. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated.MB990998
Bolt


MB990998Bolt
MB990520

BASIC BRAKE SYSTEM -Disc Brake35A-22
DISASSEMBLY AND REASSEMBLY
Front
9
11
1213
4 1
2
4
5
6 89
Brake caliper kit Pad set Seal and boot kit
55 2
3
5
110
8
76
3
9 12
97
Clip set
14
Shim set
11
6
106 31414
14
13
7
74±10 N·m
74±10 N·m 7.9±0.9 N·m
5
57Grease
Disassembly steps
"AA1. Guide pin
"AA2. Lock pin
3. Bushing
4. Caliper support (including pad, clip,
and shim)
5. Pin boot
6. Boot ring
AA"7. Piston bootAA"8. Piston
AB"9. Piston seal
10. Caliper body
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim
14. Clip