Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Eclipse & Spyder 2000-2006 Approved Mitsubishi Eclipse 2006 GR00005100-35A
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download GR00005100-35A documenatation <<
Text preview - extract from the document
35A-1
GROUP 35A
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 35A-2 BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-25
REMOVAL AND INSTALLATION . . . . . . . . 35A-25
BASIC BRAKE SYSTEM DIAGNOSIS 35A-4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-26
INTRODUCTION TO BASIC BRAKE SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 35A-4 MASTER CYLINDER ASSEMBLY
BASIC BRAKE SYSTEM DIAGNOSTIC AND BRAKE BOOSTER . . . . . . . . . . 35A-27
TROUBLESHOOTING STRATEGY . . . . . . 35A-4
REMOVAL AND INSTALLATION . . . . . . . . 35A-27
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35A-4
SYMPTOM PROCEDURES . . . . . . . . . . . . 35A-4 DISC BRAKE ASSEMBLY . . . . . . . . . 35A-30
REMOVAL AND INSTALLATION . . . . . . . . 35A-30
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-14 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-32
DISASSEMBLY AND ASSEMBLY
ON-VEHICLE SERVICE. . . . . . . . . . . 35A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . 35A-33
BRAKE PEDAL CHECK AND DISASSEMBLY AND ASSEMBLY
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 35A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A-36
BRAKE BOOSTER OPERATING TEST . . . 35A-16 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-38
CHECK VALVE OPERATION CHECK . . . . 35A-17
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-17 SPECIFICATIONS . . . . . . . . . . . . . . . 35A-40
BRAKE FLUID LEVEL SENSOR CHECK. . 35A-18 FASTENER TIGHTENING
DISC BRAKE PAD CHECK AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 35A-40
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-19 GENERAL SPECIFICATIONS . . . . . . . . . . 35A-40
DISC BRAKE ROTOR CHECK. . . . . . . . . . 35A-21 SERVICE SPECIFICATIONS . . . . . . . . . . . 35A-41
MASTER CYLINDER FUNCTION LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 35A-41
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A-24
35A-2 BASIC BRAKE SYSTEM
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1351000100688
The brake system has been designed to give greater
reliability and durability and to provide excellent brak-
ing performance.
FEATURES
3. Front- and rear-wheel X-type brake line layout
.
Improved braking performance
are used.
1. An 8+9 inch tandem brake booster provides suffi-
4. Ventilated discs on the front brakes improve
cient braking force in sudden braking range.
anti-fading performance.
2. 16-inch front ventilated disc brakes provide stable
5. Ventilated discs on the rear brakes improve
braking force and improved braking feel.
anti-fading performance. <3.8L engine>
3. 14-inch rear solid disc brakes are used.<2.4L
engine> .
4. 15-inch rear ventilated disc brakes provide stable Improved serviceability
braking force and improved braking feel. <3.8L 1. A diagnosis function for the ABS and ABS/TCL
engine> systems to make inspection easier.
.
2. An outer disc separated hub and rotor make
Improved stability removal and installation easier.
3. The master cylinder reservoir tank cap is colored
1. A 4-wheel anti-lock braking system (4ABS) pre-
white to make identification easier.
vents slipping caused by the vehicle wheels lock-
ing up, in order to maintain a stable vehicle 4. The ABS-ECU, ABS/TCL-ECU and hydraulic unit
posture and steering performance. are integrated to make them more compact and
light-weight.
2. An electronic brake-force distribution (EBD)
makes it possible to maintain the maximum
amount of braking force even when the vehicle's
load is unevenly distributed.
TSB Revision
BASIC BRAKE SYSTEM
GENERAL DESCRIPTION
35A-3
CONSTRUCTION DIAGRAM
<2.4L ENGINE>
BRAKE BOOSTER
HYDRAULIC UNIT
(INTEGRATED WITH
THE ABS-ECU)
REAR DISC BRAKE
MASTER CYLINDER
FRONT DISC BRAKE AC406018AB
<3.8L ENGINE>
BRAKE BOOSTER
HYDRAULIC UNIT
(INTEGRATED WITH
THE ABS-ECU)
REAR DISC BRAKE
MASTER CYLINDER
FRONT DISC BRAKE AC406019AB
TSB Revision
35A-4 BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS
M1351009700375
Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disc brakes. Mal-
functions such as insufficient braking power or the
generation of noise may occur due to wear, damage
or incorrect adjustment of these components.
BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1351009800350
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the symptom
basic brake system fault. chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1351009900380
SYMPTOM INSPECTION REFERENCE
PROCEDURE PAGE
Vehicle pulls to one side when brakes are applied 1 P.35A-4
Insufficient braking power 2 P.35A-5
Increased pedal stroke (Reduced pedal-to-floor board clearance) 3 P.35A-6
Brake drag 4 P.35A-7
Scraping or grinding noise when brake are applied 5 P.35A-8
Squealing, groaning or chattering noise when brake are applied 6 P.35A-10
Squealing noise when brakes are not applied 7 P.35A-10
Groaning, clicking or rattling noise when brakes are not applied 8 P.35A-13
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
.
DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad
contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part and determine the
source/cause of foreign material. Then go to
Step 5.
NO : Go to Step 2.
TSB Revision
BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
35A-5
STEP 2. Check disc brake pistons for smooth STEP 3. Check brake disc(s) for runout.
operation. Refer to P.35A-21.
(1) With engine not running, depress the brake pedal Q: Is runout outside of specifications?
rapidly several times to deplete booster vacuum YES : Repair or replace the brake disc(s) as
reserves. necessary. Then go to Step 5.
(2) Test each disc brake assembly one at a time. NO : Go to Step 4.
a. Remove the lower caliper bolt, then remove
caliper from mount.
b. Have an assistant slowly depress the brake STEP 4. Check brake discs for correct thickness.
pedal. Confirm piston(s) extend slowly and Refer to P.35A-21.
smoothly with no jumpiness. Repeat for each Q: Is the thickness outside of specifications?
disc brake assembly. YES : Repair or replace the brake disc(s) as
Q: Do (does) the piston(s) move correctly? necessary. Then go to Step 5.
YES : Go to Step 3. NO : Perform the brake line bleeding. Then go to
NO : Disassemble and inspect the brake Step 5.
assembly (Front: refer to P.35A-33, Rear:
refer to P.35A-36). Then go to Step 5. STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 2: Insufficient Braking Power
.
DIAGNOSIS STEP 2. Check for spongy (not firm) brakes.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete the booster
STEP 1. Check that the specified brake fluid is vacuum reserve.
used, its level is correct, and no contamination is (2) With the brake pedal fully released, depress the
found. brake pedal slowly until it stops.
Q: Is there a fault? (3) With a measuring device (ruler, etc.) next to the
YES : Refill or replace with the specified brake brake pedal, depress the pedal firmly and
fluid DOT 3 or DOT 4. Bleed the brakes if measure the distance the pedal traveled.
necessary (Refer to P.35A-17). Then go to
Q: Is the distance greater than 20 mm (0.8 inch)?
Step 6. YES : Bleed the brakes to remove air in the fluid
NO : Go to Step 2.
(Refer to P.35A-17). Then go to Step 6.
NO : Go to Step 3.
STEP 3. Check the brake booster function.
Refer to P.35A-16.
Q: Is there a fault?
YES : Replace the brake booster. Then go to Step
6.
NO : Go to Step 4.
TSB Revision
35A-6 BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
STEP 4. Check for pinched or restricted brake STEP 6. Recheck symptom.
tube or hose. Q: Is the symptom eliminated?
Q: Is there a pinched or restricted brake tube or hose? YES : The procedure is complete.
YES : Replace that complete section of brake tube NO : Start over at step 1. If a new symptom
or brake hose. Then go to Step 6. surfaces, refer to the appropriate symptom
NO : Go to Step 5. chart.
STEP 5. Check for oil, water, etc., on the pad
contact surfaces of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part and determine the
source/cause of foreign material. Recheck
symptom. Then go to Step 6.
NO : The procedure is complete.
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)
.
DIAGNOSIS STEP 4. Check the master cylinder function.
Refer to P.35A-24.
STEP 1. Check for spongy (not firm) brakes. Q: Is there a fault?
(1) With engine not running, depress the brake pedal YES : Repair it. Then go to Step 7.
rapidly several times to deplete booster vacuum NO : Go to Step 5.
reserve.
(2) With the brake pedal fully released, depress the STEP 5. Check for brake fluid leaks.
brake pedal slowly until it stops.
Q: Is there a leak?
(3) With a measuring device (ruler, etc.) next to the YES : Check the connection for looseness,
brake pedal, depress the pedal firmly and corrosion, etc. Clean and repair as
measure the distance the pedal traveled. necessary. If leaking in any tube or hose
Q: Is the distance greater than 20 mm (0.8 inch)? section, replace the complete tube or hose.
YES : Bleed the brakes to remove air in the fluid Then go to Step 7 .
(Refer to P.35A-17). Then go to Step 7. NO : Go to Step 6.
NO : Go to Step 2.
STEP 6. Check for excessive clearance between
STEP 2. Check the pad for wear. the push rod and primary piston.
Refer to P.35A-19. Refer to P.35A-27.
Q: Is the pad thickness outside of specifications? Q: Is the clearance outside of specifications?
YES : Replace the part. Then go to Step 7. YES : Adjust the clearance. Then go to Step 7.
NO : Go to Step 3. NO : Go to Step 7.
STEP 3. Check the vacuum hose and check valve STEP 7. Recheck symptom.
for damage.
Q: Is the symptom eliminated?
Refer to P.35A-17. YES : The procedure is complete.
Q: Is there a damage? NO : Start over at step 1. If a new symptom
YES : Replace the part. Then go to Step 7. surfaces, refer to the symptom chart.
NO : Go to Step 4.
TSB Revision
BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
35A-7
INSPECTION PROCEDURE 4: Brake Drag
.
DIAGNOSIS
STEP 1. Check the parking brake operating lever return.
Q: Is the operation faulty?
PARKING BRAKE
OPERATING LEVER
YES : Repair it. Then go to Step 9.
NO : Go to Step 2.
AC210519 AB
STEP 2. Check the brake shoe springs for breakage.
Q: Are the brake shoe springs broken?
SHOE
YES : Replace the spring. Then go to Step 9.
SPRINGS NO : Go to Step 3.
AC210519AC
STEP 3. Check the amount of grease at each sliding
section.
Refer to GROUP 36, Parking Brake Lining and Drum P.36-18.
Q: Is the grease amount low?
YES : Apply grease. Then go to Step 9.
NO : Go to Step 4.
STEP 4. Check the parking brake pull amount.
Refer to GROUP 36, On-vehicle Service -Parking Brake lever
Stroke Check and Adjustment P.36-13.
Q: Is there a fault?
YES : Adjust it. Then go to Step 9.
NO : Go to Step 5.
STEP 5. Check for insufficient clearance between the push
rod and primary piston.
Refer to P.35A-27.
Q: Is there a fault?
YES : Adjust the clearance. Then go to Step 9.
NO : Go to Step 6.
TSB Revision
35A-8 BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
STEP 6. Check the master cylinder piston return spring for
damage and return port for clogging.
Refer to P.35A-27.
Q: Is there damage?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.
STEP 7. Check port for clogging.
Q: Is the port clogged?
YES : Repair it. Then go to Step 9.
NO : Go to Step 8.
STEP 8. Check disc brake pistons for sticking.
Depress the brake pedal, then release. Confirm each wheel
spins freely.
Q: Does any wheel stick?
YES : Inspect that brake assembly. Then go to Step 9.
NO : Go to Step 9.
STEP 9. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied
.
DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for
metal-to-metal condition.
Q: Is any metal-to-metal contact evident?
YES : Repair or replace the components. Then go to Step 6.
NO : Go to Step 2.
STEP 2. Check for interference between the caliper and
wheel.
Q: Is there any interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 3.
TSB Revision
BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
35A-9
STEP 3. Check for interference between the dust cover and
brake disc.
Q: Is there any interference?
DUST COVER YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 4.
BRAKE DISC AC306518AB
STEP 4. Check the brake drums or discs for cracks.
Q: Are there cracks?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 5.
STEP 5. Check for bent backing plate(s).
Q: Is (Are) the backing plate(s) bent?
BACKING PLATE YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 6.
AC210519 AD
STEP 6. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
TSB Revision
35A-10 BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
INSPECTION PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
.
DIAGNOSIS STEP 3. Adjust the brake pedal or brake booster
pushrod.
Refer to P.35A-15 or P.35A-27.
STEP 1. Check the brake disc and pads for wear
or cutting. Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
Q: Is there wear or cutting? YES : Go to Step 4.
YES : Repair or replace the part. Then go to Step NO : Adjust the brake pedal or the brake booster
4. pushrod. Then go to Step 4.
NO : Go to Step 2.
STEP 4. Recheck symptom.
STEP 2. Check the calipers for rust.
Q: Is the symptom eliminated?
Q: Is there any rust? YES : The procedure is complete.
YES : Remove the rust. Then go to Step 4. NO : Start over at step 1. If a new symptom
NO : Go to Step 3. surfaces, refer to the symptom chart.
INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied
DIAGNOSIS
.
STEP 1. Check whether the backing plate is bent or loose
and interfering with the drum.
Q: Is there a fault?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 2.
STEP 2. Check whether the drum is damaged due to
interference with the backing plate or shoe.
Q: Is there any damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 3.
STEP 3. Check the brake drum for wear and the shoe
spring for damage.
Q: Is there any wear or damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 4.
STEP 4. Check the brake discs for rust.
Q: Are the brake discs rusted?
YES : Remove the rust by using sand paper. If still rusted,
turn the rotors with an on-the-car brake lathe. Then go
to Step 10.
NO : Go to Step 5.
TSB Revision
BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
35A-11
STEP 5. Check the brake pads for correct installation.
Q: Are the pads installed incorrectly?
YES : Repair the pads. Then go to Step 10.
NO : Go to Step 6.
STEP 6. Check the calipers for correct installation.
Q: Are the calipers installed incorrectly?
YES : Repair the calipers. Then go to Step 10.
NO : Go to Step 7.
STEP 7. Check the wheel bearings for end play.
(1) Remove the brake discs.
(2) 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)
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 10.
NO : Go to Step 8.
AC102438 AC
AC205869AC
STEP 8. Check whether the brake booster or master
cylinder return is insufficient.
Q: Is the brake booster or master cylinder return
insufficient?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 9.
STEP 9. Adjust the brake pedal or brake booster pushrod.
Refer to P.35A-15 or P.35A-27.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES : Go to Step 10.
NO : Adjust the brake pedal or the brake booster pushrod.
Then go to Step 10.
TSB Revision
35A-12 BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
STEP 10. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
TSB Revision
BASIC BRAKE SYSTEM
BASIC BRAKE SYSTEM DIAGNOSIS
35A-13
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 ◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo