Mitsubishi Montero (1991+). Manual — part 52
to the conditions that follow, you may suggest rebuilding or
replacement of the other wheel cylinder (on the same axle) for
preventive maintenance, for example, the part is close to the end of
its useful life.
Determine the need to rebuild or replace based upon the
individual wheel cylinder conditions that follow.
WHEEL CYLINDER INSPECTION
Condition Code Procedure
Attaching hardware bent . B . . Require replacement of bent
parts.
Attaching hardware
broken . . . . . A ... Require repair or replacement
of hardware.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
parts.
Attaching hardware
loose . . . . .. A .. Require repair or replacement.
Attaching hardware
missing . . . . C . . .. Require replacement of
hardware.
Attaching hardware not
functioning . . . A ... Require repair or replacement
of hardware.
Bleeder port damaged (if
non-repairable) . . A . . . Require replacement.
Bleeder screw broken off
in wheel cylinder (if non-
repairable) . . . A . . (1) Require replacement.
Bleeder screw plugged ... A . . ... ( 1) Require repair or
replacement of bleeder screw.
Bleeder screw seized . A . . (2) Require replacement.
Bore corroded (pitted) .. B . . . Require replacement.
Bore grooved . . . A . . . Require replacement.
Bore oversized . . .. B . . . Require replacement.
Dust boot missing . ... C . . Require replacement of dust
boot.
Dust boot torn . . .. A . (3) Require replacement of dust
boot.
Leaking . . . . . A . ... (4) Require rebuilding or
replacement.
Piston corroded, affecting
performance . . . B ... Require replacement of piston
and rebuilding or replacement
of wheel cylinder.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement
of wheel cylinder.
Piston stuck in bore . A . Require replacement of wheel
cylinder.
Loose . . . . ... B .. Require repair or replacement.
Threads damaged . . . A .. Require repair or replacement.
Threads stripped (threads
missing) . . . ... A . . . Require replacement.
(1) - Only required if the hydraulic system must be opened.
(2) - Seized is defined as bleeder screw that cannot be removed
after a practical attempt at removing. Only required if
the hydraulic system must be opened.
(3) - Inspect for conditions related to wheel cylinder.
(4) - Leaking is defined as a drop or more. Dampness is normal.
WIRING HARNESSES
NOTE: Copied from Electrical UIGs.
WIRING HARNESS INSPECTION
Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Attaching hardware
broken . . . . . A ... Require repair or replacement
of hardware.
Attaching hardware
missing . . . . C . . .. Require replacement of
hardware.
Attaching hardware not
functioning . . . A ... Require repair or replacement
of hardware.
Connector broken . . A .. Require repair or replacement.
Connector (Weatherpack
type) leaking . . .. A .. Require repair or replacement.
Connector melted . . A . . ... ( 1) Require repair or
replacement.
Connector missing . ... C . . . Require replacement.
Insulation damaged,
conductors exposed . . A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 . . . Suggest replacement.
Open . . . . . A .. Require repair or replacement.
Protective shield
(conduit) melted . ... 2 . . ... ( 1) Suggest repair or
replacement.
Protective shield
(conduit) missing . .. 2 .. Suggest repair or replacement.
Resistance (voltage drop)
out of specification ... A .. Require repair or replacement.
Routed incorrectly . .. B . . . . . Require repair.
Secured incorrectly . . B . . . . . Require repair.
Shorted . . . . . A .. Require repair or replacement.
Terminal broken . . . A .. Require repair or replacement.
Terminal burned, affecting
performance . . . A . . ... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance . . . B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Voltage drop out of
specification . . .. A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
BRAKE SYSTEM
1991 Mitsubishi Montero
1991 BRAKES
Disc & Drum
Chrysler Motors: Ram-50;
Mitsubishi: Montero, Pickup
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 BRAKE SYSTEM
BLEEDING PROCEDURES
Montero
Bleed brake system in following order: right rear, right
front and left front (one circuit handles both rear brakes).
Pickup & Ram-50
Bleed brake system in following order: right rear, left rear,
LSPV, right front and left front.
ADJUSTMENTS
BRAKE PEDAL HEIGHT & FREE PLAY
1) Separate connector from stoplight switch, and loosen lock
nut. Position switch so it does not contact brake pedal arm. Adjust
brake pedal height by rotating master cylinder push rod (yoke, if
equipped) until distance from top of brake pedal to floor board is
correct. See BRAKE PEDAL SPECIFICATIONS table.
2) DO NOT depress push rod. Tighten lock nut, and ensure
brake pedal height is within specification. Start engine to evacuate
brake booster chamber. Stop engine, and apply brake several times to
remove vacuum from brake booster.
3) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. If distance is incorrect, bleed the
brake hydraulic system, and check for misadjusted brakes. Refer to the
BRAKE PEDAL SPECIFICATIONS table.
BRAKE PEDAL SPECIFICATIONS TABLE
Free Play Pedal Height
Application In. (mm) In. (mm)
Montero . . . .12-.31 (3-8) ... 7.5-7.7 (191-196)
Pickup & Ram-50 . .12-.31 (3-8) . . ... 6.5 (166)
LOAD-SENSING PROPORTIONING VALVE (LSPV) (Pickup & Ram-50)
Park vehicle on level surface. Remove all luggage and
passengers. Ensure lever is not against stopper bolt. Check spring
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