Brake System: 1991 Mitsubishi Montero
Brake System: 1991 Mitsubishi Montero
Brake System: 1991 Mitsubishi Montero
1991 BRAKES
Disc & Drum
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake unit, proportioning valve and self-adjusting assembly. Pickup
and Ram-50 models have a Load-Sensing Proportioning Valve (LSPV). All
models are equipped with front disc brakes and rear drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING PROCEDURES
Montero
Bleed brake system in following order: right rear, right
front and left front (one circuit handles both rear brakes).
ADJUSTMENTS
PARKING/EMERGENCY BRAKE
NOTE: Adjust service brake before adjusting parking brake.
Montero
1) Start engine, and apply brake pedal. Pull parking brake
lever with a force of 44-45 lbs. (20.0-20.4 kg). Parking brake lever
should move up 4-6 notches.
2) If necessary, turn adjusting cable nut located under
console or at end of cable rod. See Fig. 3.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
.02-.04" (.5-1.0 mm). Tighten lock nut. DO NOT depress master cylinder
push rod during stoplight switch adjustment.
TESTING
System Check
1) Run engine for 2 minutes, and shut it off. Depress brake
pedal several times with normal pressure. If pedal height gradually
becomes higher with successive applications, power brake unit is okay.
If pedal height remains steady, power brake unit is faulty.
2) With engine stopped, depress brake pedal repeatedly until
it’s height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake unit is okay. If pedal
height does not change, power brake unit is faulty.
3) With engine running, press and hold brake pedal and shut
off engine. Hold brake pedal for 30 seconds. Brake pedal height should
not change. If pedal height falls, power brake unit is faulty.
Load-Sensing Spring
Removed ........... 853 (60) ......... 242-327 (17-23)
Installed ........ 1991 (140) .... ( 1) 299-583 (21-40)
(1) - On vehicles with 2WD and heavy-duty suspension,
outlet pressure is 526-697 psi (37-49 kg/cm ).
2.6L
Test 1 ............ 853 (59) ......... 473-526 (33-37)
Test 2 ........... 1280 (88) ......... 672-757 (46-52)
3.0L
2-Door Model
Test 1 .......... 853 (59) ......... 473-526 (33-37)
Test 2 ......... 1565 (108) ........ 768-865 (54-60)
4-Door Model
Test 1 .......... 597 (41) ......... 569-626 (39-43)
Test 2 ......... 1377 (95) ......... 843-928 (58-64)
(1) - Maximum side-to-side pressure differential
is 57 psi (4kg/cm ).
Removal
1) Raise and support vehicle. Remove front wheel(s). Remove
lower lock pin or sleeve bolt. See Fig. 6. Lift caliper body upward.
2) Support caliper using wire. Remove shim(s), shim holder
(if equipped), anti-squeak shim and pad assembly from support
mounting. Remove pad clips.
Installation
If installing new pads, compress piston to bottom of bore.
Install retaining clips, pad assembly, shim(s), shim holder (if
equipped) and anti-squeak shim onto support mounting.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See the TORQUE SPECIFICATIONS table. Bleed brake
system. See BLEEDING BRAKE SYSTEM.
Installation
1) Install front hub assembly. Install and tighten lock nut
to 94-145 ft. lbs. (127-197 N.m), and then loosen and retighten to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Reverse removal
procedure for remaining components. After installation is complete,
check drive axle end play. Adjust end play if not .002" (.05 mm) or
less. Rotate drive axle forward and rearward until maximum end play is
obtained.
2) If adjusting axle shaft end play, use proper shim to
obtain desired end play. Shim is located behind snap ring on end of
drive axle. Install shim, and recheck axle end play.
Installation
1) To install, reverse removal procedure. Apply Lubriplate to
backing plate bosses, adjuster assembly threads and parking brake
lever pin.
2) Set adjustment assembly so brake shoes lightly contact
brake drum. Depress brake pedal to center shoes, and check pedal
travel. Rotate brake drum to ensure free movement.
WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES under REMOVAL & INSTALLATION. Remove wheel
cylinder and seal assembly. To install, reverse removal procedure.
Bleed brakes.
MASTER CYLINDER
Removal
Drain brake fluid from master cylinder. Remove sensor
connector (if equipped). Disconnect brake lines from master cylinder,
and install plugs to prevent brake fluid spillage. Remove master
cylinder from booster unit and separate reservoirs from housing (if
necessary).
Installation
To install, reverse removal procedure. Before installation,
check and adjust clearance between back of master cylinder piston and
power brake push rod. Refer to MASTER CYLINDER PUSH ROD under
ADJUSTMENTS. After installation, adjust the brake pedal height. Refer
to BRAKE PEDAL HEIGHT & FREE PLAY under ADJUSTMENTS. Bleed brake
system. See BLEEDING BRAKE SYSTEM.
POWER BRAKE UNIT CHECK VALVE
NOTE: To test check valve before removal, stop engine, and apply
service brake to ensure air flows only toward intake
manifold.
Installation
To install, reverse removal procedure. Install master
cylinder. Bleed brake system if necessary.
Installation
1) Apply Multipurpose Grease (SAE J310) to oil seal. Install
oil seal using seal driver. Apply grease to outside circumference of
bearing outer race. Apply grease to lip of oil seal and to roller
surfaces of bearing inner race.
2) Press bearing onto axle shaft. Install rear brake assembly
and bearing case. Pack bearing case and axle threads with grease.
Install lock washer (tab aligned with axle slot) and lock nut (chamfer
toward lock washer). Tighten lock nut to 130-159 ft. lbs. (176-216 N.
m).
3) Bend tabs on lock washer into slots of lock nut. Apply
grease to oil seal area of rear axle housing. Adjust clearance between
bearing case and rear axle by inserting .04" (1.0 mm) shim and "O"
ring into left rear axle housing.
4) Apply semi-drying sealant to mating surface of bearing
case. Install left axle shaft into rear housing. Tighten nuts
diagonally to 36-43 ft. lbs. (49-58 N.m).
5) Install right axle shaft without shims and "O" ring.
Temporarily tighten to about 53 INCH lbs. (6 N.m). Using a feeler
gauge, measure clearance between bearing case and rear axle housing.
6) Remove right axle shaft. Install shims to equal bearing
case-to-axle housing clearance plus .002-.008" (.05-.20 mm). Install
"O" ring to right rear axle housing. Apply sealant to mating surfaces
of bearing case and shim. See Fig. 10.
7) Install axle into housing, tightening nuts diagonally to
36-43 ft. lbs. (50-58 N.m). Check axle shaft for .002-.008" (.05-.20
mm) end play using dial indicator.
Installation
1) Apply Multipurpose Grease (SAE J310) to oil seal. Install
oil seal using seal driver. Apply grease to outside circumference of
oil seal lip. Install backing plate and bearing case. Apply grease to
oil seal.
2) Press new oil seal into bearing case until it is flush
with face of bearing case. Apply grease to lip of oil seal and to
external surfaces of bearing outer race. Press bearing outer race into
bearing case.
3) Apply grease to roller surfaces of bearing inner race.
Install rear brake assembly and bearing case. Pack bearing case and
axle threads with grease. Install new retainer ring.
4) Adjust clearance between bearing case and rear axle by
inserting .04" (1.0 mm) shim and "O" ring into left rear axle housing.
Apply semi-drying sealant to mating surface of bearing case. Install
left axle shaft into rear housing. Tighten nuts diagonally to 36-43
ft. lbs. (50-58 N.m).
5) Install right axle shaft without shims and "O" ring.
Temporarily tighten to about 53 INCH lbs. (6 N.m). Using a feeler
gauge, measure clearance between bearing case and rear axle housing.
6) Remove right axle shaft. Install shims to equal bearing
case-to-axle housing clearance plus .002-.008" (.05-.20 mm). Install
"O" ring to right rear axle housing. Apply sealant to mating surface
of bearing case. See Fig. 10.
7) Install axle into housing, tightening nuts diagonally to
36-43 ft. lbs. (49-58 N.m). Check axle shaft for .002-.008" (.05-.20
mm) end play using dial indicator.
OVERHAUL
NOTE: For exploded views of front disc brake caliper, see Fig. 12.
For exploded view of master cylinder, see Fig. 13.
Disc Diameter
Montero
2.6L ...................................... 10.2 (259)
3.0L ...................................... 10.9 (277)
Pickup & Ram-50
2WD ....................................... 10.2 (259)
4WD ....................................... 10.9 (277)
Lateral Runout ................................ .006 (.15)
Parallelism .......................................... ( 1)
Original Thickness .............................. .87 (22)
Master Cylinder Diameter .................... .938 (23.83)
Minimum Refinish Thickness .................... .80 (20.4)
Discard Thickness ............................. .78 (19.8)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE
Application Ft. Lbs. (N.m)