1990 Mitsubishi Mighty MAX Brake Service (ONLINE REPAIR MANUALS)

REMOVAL

• Remove wheel, drum and brake shoes.
• Loosen brake line fitting at wheel cylinder. Do not pull metal line away from cylinder.
• Remove screw holding cylinder to backing plate.
• Separate wheel cylinder from brake line and backing plate by pulling the cylinder outward and away from backing plate.

OVERHAUL

Note position of all parts as they are removed for proper installation.

Disassembly

• Refer to Fig. , then remove boots, piston, cups and spring from wheel cylinder.
• Wipe cylinder walls with denatured alcohol or clean brake fluid.
• Examine cylinder bore. A scored bore may be providi...

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...

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...

2WD

• Disconnect battery ground cable.
• Raise and support vehicle.
• Remove front brake assembly and suspend assembly with wire.
• Remove hub cap, then the cotter pin.
• Remove slotted nut and washer, then the outer bearing.
• Remove front hub and rotor assembly.
• Reverse procedure to install adjusting wheel bearing as follows:
• Torque slotted nut to 22 ft. lbs.
• Loosen slotted nut completely.
• Retorque slotted nut to 6 ft. lbs.

4WD

• Place free wheeling hub in "Free" position.
• Rotate hub cover counterclockwise and remove.
• Remove snap ring from end of driveshaft.
• Remove adjusting shims (if equipped).
• Remove ...

EXCEPT DIAMANTE & VAN/WAGON

• Disconnect brake fluid sensor electrical connector from master cylinder reservoir.
• Position a drain pan under the master cylinder.
• On models with separately mounted reservoir, disconnect reservoir hoses from the master cylinder.
• On all models, use a suitable wrench to disconnect brake lines from the master cylinder. Plug all lines and fittings.
• Remove master cylinder-to-brake booster attaching nuts.
• Pull master cylinder outward and away from brake booster.
• Reverse procedure to install noting the following:
• Prior to master cylinder installation, ad...

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...