1990 Mitsubishi Mighty MAX Brake Service (ONLINE REPAIR MANUALS)

Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal.

• Ensure master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap.
• Raise and support vehicle.
• Position a drain pan under the wheel being bled.
• Have an assistant depress the brake pedal w...

• Raise and support vehicle, then remove front wheel.
• Remove lockpin bolt, Fig. through .
• Lift up caliper body, using the guide pin bolt as a fulcrum. Use wire to suspend the caliper.
• Remove inner and outer shims, pad assemblies, and pad clips from caliper support.
• Measure hub torque, using suitable spring scale, to determine brake drag torque after pan installation, Fig. .
• Inspect all components, replacing as necessary.
• Clean exposed part of piston, then compress piston.
• Reverse procedure to install,...

TESTING

Except Pickup, Van/Wagon & 1992 Montero

• Connect two pressure gauges to proportioning valve, one to the output side and one to the input side, Fig. .
• Bleed system after connecting gauges.
• Depress brake pedal, check that measured values are within specifications as shown in "Specifications".

Pickup, Van/Wagon & 1992 Montero

• Check load proportioning valve spring length with vehicle on flat ground.
• Press load sensor lever and measure distance between spring ends, Fig. .
• On all models except 1992 Montero, distance should be between 6.93-7.05 inch. On 1992 Montero distance should be...

The vacuum assist diaphragm assembly multiplies the force exerted on the master cylinder piston in order to increase the hydraulic pressure delivered to the wheel calipers while decreasing the effort necessary to obtain acceptable stopping performance.

Vacuum assist units get their energy by opposing engine vacuum to atmospheric pressure. A piston, cylinder and f...

On models with airbags, serious injury can result from unintended airbag deployment.

To disarm the airbag, disconnect, tape and isolate the battery ground cable. Wait at least 30 seconds before any further work is attempted. The Supplemental Restraint System (SRS) is designed to retain sufficient voltage to deploy the airbag for a short time after the battery has been disconnected. Serious injury may result from unintended airbag deployment if service is attempted immediately after battery ground cable is disconnected.

After service is completed, ensure no one is inside of v...

EXCEPT 1992 MONTERO

• Remove dust boot.
• Cover inner side of caliper with rag, then slowly inject compressed air through brake hose fitting to push out piston.
• Remove piston seal, being careful not to damage cylinder.
• Clean all metal parts and piston seal with brake fluid and clean dust boot with alcohol.
• Check components for wear or damage, replacing as necessary. Use new piston seal, dust boot, and boot ring.
• Apply rubber grease supplied with repair kit to piston seal, fit seal into cylinder groove, and install piston by hand, being careful not to twist seal.
• Apply grease supplied with ...