.

BRAKEOPERATING SYSTEM 9-2 BASIC OPERATING PRINCIPLES 9-2 DISCBRAKES 9-2 DRUM BRAKES9-2 POWERBOOSTERS 9-2 BRAKE LIGHT SWITCH 9-3 REMOVAL&INSTALLATION 9-3 MASTER CYLINDER9-3 REMOVAL&INSTALLATION 9-3 ' BRAKE PEDAL ADJUSTMENTS 9-4 POWER BRAKEBOOSTER 9-5 REMOVAL &INSTALLATION 9-5 PROPORTIONING 9-6 VALVE REMOVAL &INSTALLATION 9-6 BRAKEHOSESAND LINES 9-6 REMOVAL&INSTALLATION 9-6 BLEEDING BRAKESYSTEM 9-7 DISCBRAKES 9-8 BRAKE PADS 9-8 REMOVAL &INSTALLATION 9-8 INSPECTION 9-11 BRAKE CALIPER9-11 REMOVAL INSTALLATION & 9-11 OVERHAUL 9-12 BRAKE (ROTOR)9-13 DISC REMOVAL &INSTALLATION 9-13 INSPECTION 9-14 DRUMBRAKES 9-15 BRAKEDRUMS 9-16 REMOVAL &INSTALLATION 9-16 INSPECilON 9-16 BRAKESHOES 9-16 INSPECTION 9-16 REMOVAL&INSTALLATION 9-17 ADJUSTMENTS 9-18 WHEELCYLINDERS 9-19 REMOVAL &INSTALLATION 9-19 OVERHAUL 9-19 PARKING BRAKE 9-20 CABLE(S)9-20 REMOVAL&INSTALLATION 9-20 ADJUSTMENT 9-22 BRAKESHOES 9-23 REMOVAL &INSTALLATION 9-23 ADJUSTMENT 9-24 ANTI-LOCKBRAKE SYSTEM 9-24 GENERAL INFORMATION 9-24 PRECAUTIONS 9-24 DIAGNOSIS TESTING9-24 AND HYDRAULIC CONTROL UNIT 9-25 REMOVAL&INSTALLATION 9-25 ANTI-LOCK CONTROL UNIT 9-27 REMOVAL&INSTALLATION 9-27 SPEED SENSORS9-28 REMOVAL &INSTALLATION 9-28 bG-SENSOR9-29 REMOVAL &INSTALLATION 9-29 ' TONE (EXCITER) RING 9-29 REMOVAL&INSTALLATION 9-29 BLEEDINGTHEABSSYSTEM 9-30

COMPONENTLOCATIONS DRUM BRAKECOMPONENTS 9-15 SPECIFICATIONS CHARTS ABSDIAGNOSTICTROUBLE 9-25 CODES BRAKE SPECIFICATIONS 9-31

9-2 BRAKES
the time the pedalis in the released positionthat any fluid that hasleakedout of the systemwill be replacedthroughthe compensating ports. Dualcircuit mastercylindersemploytwo pistons, locatedone behindthe other, in the samecylinder. The primarypiston is actuated directly by mechanical linkagefrom the brakepedalthroughthe power booster.Thesecondarypiston is actuatedby fluid trappedbetween two pistons.If a leakdevelopsin the front of the secondarypiston, it movesforwarduntil it bottomsagainstthe front of the mastercylinder,and the fluid trappedbetween pistonswill operatethe the rear brakes.If the rearbrakesdevelopa leak,the primarypiston will moveforwarduntil directcontact with the secondarypistontakesplace,and it will force the secondarypistonto actuatethe front brakes. In eithercase,the brakepedalmovesfartherwhenthe brakesareapplied,and lessbrakingpoweris available. All dual circuit systemsusea switchto warnthe driver whenonly half of the brakesystemis operational. This switch is usuallylocatedin a valve body which is mountedon the firewall or the framebelow the mastercylinder.A hydraulicpiston receivespressurefrom both circuits, eachcircuits pressurebeing appliedto oneend of the piston.Whenthe pressures are in balance, piston remainsstationary.When the onecircuit hasa leak,however,the greaterpressure in that circuit during applicationof the brakeswill pushthe piston to oneside, closing the switchand activatingthe brakewarninglight. In disc brakesystems,this valve bodyalso containsa meteringvalve and, in somecases,a proportioning valve. Themeteringvalve keepspressure from travelingto the disc brakeson the front wheels until the brakeshoeson the rearwheelshavecontactedthe drums,ensuringthatthe front brakeswill neverbe usedalone.The proportioningvalve controls the pressureto the rearbrakesto lessenthe chanceof rearwheellock-up duringvery hard braking. Warninglights may betestedby depressing the brakepedaland holding it while openingone of the wheelcylinder bleederscrews.If this doesnot cause the light to go on, substitutea newlamp,makecontinuity checks,and,finally, replacethe switchas necessary. checkedfor leaks by The hydraulicsystemmay be applyingpressureto the pedalgraduallyand steadily. If the pedalsinks very slowlyto the floor, the system hasa leak.This is not to beconfusedwith a springy or spongyfeel dueto the compressionof air within the lines. If the systemleaks,therewill be a gradual changein the position of the pedalwith a constant pressure. Checkfor leaksalong all lines and at wheelcylinders. If no externalleaksare apparent, problemis the insidethe mastercylinder, principle but applythe brakingeffortto a separate disc insteadof the wheel. Thedisc (rotor) is a casting,usuallyequippedwith cooling fins between two brakingsurfaces. the This enablesair to circulatebetween brakingsurfaces the makingthem lesssensitiveto heatbuildupand more resistantto fade.Dirt and waterdo not drasticallyaffect brakingactionsince contaminants thrown off are by the centrifugalaction of the rotor or scrapedoff the by the pads.Also, the equalclampingactionof the two brakepadstendsto ensureuniform,straight line stops. Disc brakesare inherentlyself-adjusting. Therearethreegeneraltypes of disc brake: 1. A fixed caliper. 2. A floatingcaliper. 3. A sliding caliper. Thefixed caliperdesignusestwo pistons mountedon eitherside of the rotor (in eachside of the caliper).Thecaliper is mountedrigidly and does not move. Thesliding and floatingdesignsare quite similar. In fact,thesetwo typesare often lumpedtogether.In both designs,the padon the insideof the rotor is movedinto contactwith the rotor by hydraulicforce. Thecaliper,which is not held in a fixed position, movesslightly, bringingthe outsidepad into contact with the rotor.Therearevarious methodsof attaching floating calipers.Somepivot at the bottomor top, and someslide on mountingbolts. In any event,the end resultis the same.

Hydraulicsystemsare usedto actuatethe brakes of all modernautomobiles.Thesystemtransportsthe powerrequiredto forcethe frictional surfacesof the brakingsystemtogetherfrom the pedalto the individual brakeunits at eachwheel.A hydraulicsystem is usedfor two reasons. First,fluid underpressurecan be carriedto all partsof an automobileby small pipesand flexible hoseswithout taking up a significantamountof room or posing routing problems. Second,a greatmechanical advantage be can givento the brakepedalend of the system,and the foot pressurerequiredto actuatethe brakescan be reducedby makingthe surfaceareaof the master cylinderpistonssmallerthanthat of anyof the pistons in the wheelcylindersor calipers. The mastercylinderconsistsof a fluid reservoir alongwith a doublecylinderand piston assembly. Doubletype mastercylindersare designedto separatethe front and rear brakingsystemshydraulically in caseof a leak.The mastercylinderconvertsmechanicalmotionfrom the pedalinto hydraulicpressurewithin the lines.This pressureis translated back into mechanicalmotionat the wheelsby eitherthe wheelcylinder(drum brakes)or the caliper(disc brakes). Steellines carrythe brakefluid to a point on the vehiclesframeneareachof the vehicleswheels.The fluid is thencarriedto the calipersand wheelcylinders by flexibletubesin orderto allow for suspension and steeringmovements. In drum brakesystems,eachwheelcylindercontains two pistons,oneat eitherend,which pushoutward in oppositedirectionsand forcethe brakeshoe into contactwith the drum. In disc brakesystems,the cylindersare part of the calipers.At leastonecylinder in eachcaliperis used to forcethe brakepadsagainstthe disc. All pistonsemploysometype of seal,usually madeof rubber,to minimizefluid leakage. rubber A dust boot sealsthe outerend of the cylinderagainst dustand dirt. The bootfits aroundthe outerend of the piston on disc brakecalipers,and aroundthe brakeactuatingrod on wheelcylinders. The hydraulicsystemoperatesas follows: Whenat rest,the entiresystem,from the piston(s) in the master cylinderto those in the wheelcylindersor calipers,is full of brakefluid. Uponapplicationof the brakepedal,fluid trappedin front of the mastercylinder piston(s) is forcedthroughthe lines to the wheel cylinders.Here,it forcesthe pistonsoutward,in the caseof drum brakes,and inwardtowardthe disc, in the caseof disc brakes.Themotion of the pistons is opposedby returnspringsmountedoutsidethe cylindersin drum brakes,and by spring seals,in disc brakes. Uponreleaseof the brakepedal,a spring located insidethe mastercylinderimmediatelyreturnsthe mastercylinderpistonsto the normalposition.The pistonscontaincheckvalvesand the mastercylinder I hascompensating ports drilled in it. Theseare uncoveredas the pistons reachtheir normalposition. The piston checkvalves allow fluid to flow towardthe wheelcylindersor calipersas the pistonswithdraw. Then,as the returnspringsforce the brakepadsor shoesinto the releasedposition,the excessfluid reservoirthroughthe compensating ports. It is during

DRUM BRAKES
Drumbrakesemploytwo brakeshoesmountedon a stationarybackingplate.Theseshoesare positioned insidea circulardrum which rotateswith the wheelassembly. shoesare held in placeby The springs.This allowsthemto slide towardthe drums (whentheyare applied)while keepingthe linings and drums in alignment.Theshoesare actuated a by wheelcylinderwhich is mountedat the top of the backingplate.Whenthe brakesareapplied,hydraulic pressureforcesthe wheelcylindersactuatinglinks outward.Sincetheselinks beardirectlyagainstthe top of the brakeshoes,the tops of the shoesare then forcedagainstthe innerside of the drum.This action forcesthe bottomsof the two shoesto contactthe brakedrum by rotatingthe entireassemblyslightly (knownas servo action).Whenpressure within the wheelcylinderis relaxed,returnsprings pull the shoesbackawayfrom the drum. Most moderndrum brakesare designedto selfadjustthemselvesduringapplicationwhenthe vehicle is moving in reverse.This motion causesboth shoesto rotatevery slightlywith the drum, rocking an adjustinglever,therebycausingrotationof the adjusting screw.Somedrum brakesystemsare designedto self-adjustduringapplicationwheneverthe brakesareapplied.This on-boardadjustment system reducesthe needfor maintenance adjustments and keepsboth the brakefunctionand pedalfeel satisfactory.

DISC BRAKES
Insteadof the traditionalexpandingbrakesthat pressoutwardagainsta circulardrum,disc brake systemsutilizea disc (rotor) with brakepadspositioned on eitherside of it. An easily-seenanalogyis the handbrakearrangement a bicycle.The pads on squeeze the rim of the bikewheel,slowing its onto motion.Automobiledisc brakesusethe identical

POWER BOOSTERS
Virtuallyall modernvehiclesusea vacuumassisted powerbrakesystemto multiplythe braking forceand reducepedaleffort.Sincevacuumis always availablewhenthe engineis operating, systemis the

BRAKiS 9-3
simple efficient. vacuum and A diaphragmlocated is onthefrontof themaster cylinder assists driand the verinapplying brakes, the reducing theeffort both andtravel must intomoving brake he put the pedal. Thevacuum diaphragm housing normally is connetted theintake to manifold avacuum A by hose. check is placed thepointwhere hose valve at the entersthediaphragm housing, thatduring so periods Of lowmanifold vacuum brakes will notbelost. assist Depressing brake closes thevacuum the pedal off source allows and atmospheric pressure enter to on onesideof thediaphragm. causes master This the cylinder pistons move apply brakes. to and the When thebrake is released, pedal vacuum applied is to bothsides thediaphragm springs of and return the diaphragm master and cylinder pistons thereto leased position. If thevacuum supply thebrake rodwill fails, pedal contact endof themaster the cylinder actuator rod andthesystem apply brakes will the without any power assistance. driver notice much The will that higher effortis needed stopthecarandthat pedal to thepedal harder usual. feels than Vacuumleak Test 1. Operate engine idlewithout the at touching the brake for at least minute. pedal one 2. Turnofftheengine waitoneminute. and 3. Test thepresence assist for of vacuum deby pressing brake andreleasingseveral the pedal it times. vacuum present thesystem, appliIf is in light cation produce andlesspedal will less travel. there If is novacuum, is leaking thesystem. air into SystemOperationTest 1. With engine pump brake the OFF, the pedal untilthesupply vacuum entirely is gone. 2. Putlight,steady pressure thebrake on pedal. 3. Start engine letit idle.If thesystem the and is operating correctly, brake should tothe pedal fall ward floorif theconstant the pressure maintained. is Power systems betested hydraulic brake may for leaks asordinary just systems tested. are gine.Have assistant an observe brake atthe the lights rear thevehicle youpush thebrake of while on pedal. Thelightsshould onjustasthebrake come pedal passes pointoffreeplay. the 9. Adjust brake switch necessary. the light as The small amount freeplayinthepedal of should not

REMOVAL &INSTALLATION
) See Figures2 thru 10

3MASTER188A11Ly N-0s . KLNsIMEm CLWRANCE BETWEEN BRAKE WOSTER PUSHROOPISTCU AN0 PRIMARY

REMOVAL&INSTALLATION
$ See Figure 1 1. Disconnect negative the battery cable. 2. Detach stoplamp the switch electrical harness connector. 3. Loosenthe locknut holding switch the the to bracket. Remove locknut theswitch. the and To install: 4. Install new the switch install locknut, and the tighteningjustsnug. it 5. Reposition brake switch thatthe the light so distance between outer of theswitch the the case and pedal 0.02-0.04 (0.5-l .Omm). thatthe is in. Note switch plunger press must against pedal keep the to thebrake off.Asthepedal lights moves from away theswitch, plunger the extends closes and the switch, which onthestoplights. turns 6. Holdtheswitch thecorrect in position and tighten locknut. the 7. Connect wiringto theswitch. the 8. Check operation theswitch. theigthe of Turn nitionkeytotheONposition donotstart enbut the

9-4 BRAKES

Fig 8 Unfasten the master cylinder-topower booster retaining nuts . . . F57g6~ 1. Disconnect negative the battery cable. 2. Remove master the cylinder reservoir cap, thenusea clean turkey baster equivalent siphon or to outasmuch aspossible place a suitable fluid and in container. thecap. Install

Fig. 9 . . . then removethe mastercylinder assemblyfrom the vehicle antevalue become will 0.004-0.012 in. (0.1-0.3mm). the cylinder thebrake to 9. install master booster, install retaining Tighten then the nuts. the nuts 7 ft. Ibs.(10Nm). to 10. Install master the cylinder reservoir, securing theretainers. 11. Attach fluidlevel the sensor connector, then unplug connect fluidlinesto thereservoir. and the 12. Theremainder installation thereverse of is of theremoval procedure. thereservoir the Fill with proper andamount DOT brake froma type of 3 fluid fresh, sealed container.
I l

Fig. 10 The brake booster pushrodand prfmary piston clearance(A) must be adjusted Measure brake height thefloorof the pedal from thevehicle theupper to surface thebrake of pedal. Thedistance should 6.9-7.1in (176181mm). be If thebrake height incorrect, asfollows: pedal is adjust 1. Detach stoplamp the switch connector. 2. Loosen locknut thebase thestop the on of lightswitch move switch a position and the to where it does contact brake not the pedal. 3. Loosen operating locknut. the rod Adjust the height thebrake byturning operating of pedal the rod using pliers. thedesired height obOnce pedal is tained, tighten locknut theoperating the on rod. 4. Screw stoplightswitch theit contacts the until thebrake stopper. switch untilthe pedal Turn in brake juststarts move. thispoint, pedal to At return (loosen) stoplight the switch turnandsecure $-1 in thisposition tightening locknut. thisposiby the In tion,thedistance between lower lightswitch the stop case thebrake stopshould 0.02-0.04 and pedal be in.(0.5-l .Omm). 5. Attach electrical the connector thestoplight to switch. 6. Check besure thestoplights notilto that are luminated nopressure thebrake with on pedal. 7. Without starting vehicle, the depress brake the pedal. thebrake switch properly If light is connected, thebrake will illuminate. lights BrakePedal Free-Play II See Figure 14 1. Withtheengine depress brake off, the pedal fullyseveral to evacuate vacuum the times the in booster. 2. Once thevacuum hasbeen all assist eliminated, thebrake down hand conpress pedal by and

Brakefluid containspolyglycol ethersand polyglycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If you do get brakefluid in your eyes, flush your eyes with clean, runningwater for 15 minutes.If eye irritation persists, or if you havetaken brakefluid internally, IMMEDIATELY medicalassistance. seek 3. Disconnect plugthelinesfromthebrake and master cylinder reservoir. 4. Detach fluidlevel the sensor connector, unfasten retainers, remove master the then the cylinder reservoir. 5. Forvehicles equipped manual with transaxle, remove clutch the master cylinder reservoir bracket. 6. Disconnect plugthebrake fromthe and lines master cylinder. 7. Unfasten master the cylinder-to-power booster retainino thenremove master nuts, the cvlin-, derfromthevefiicle. To install: 8. Adjust clearance between brake the (A) the booster pushrod I theprimary ant piston follows: as a. Calculate clearance fromtheB,C tlle A andD measurements, asshown theaccompain nyingfigure.A equals minus minus B C i D. b. Theclearance should 0.256-t in. be I.335 (0.65-0.858mm). brake When booster Inegative pressure psi(67kPa)is applied, clear9.7 then

Clean, high quality brakefluid is essentialto the safe and properoperationof the brake system.Youshouldalways buythe highest quality brakefluid that is available. If the brakefluid becomescontaminated,drain and flush the system,then refill the mastercylinder with new fluid. Never reuseany brake fluid. Any brakefluid that is removedfrom the systemshouldbe discarded.Also, do not allow any brakefluid to comein contactwith a paintedsurface; it will damagethe paint. 13. Bleed brake the system, outlined in as later thissection. 14. Adjust brake the pedal, outlined in as later thissection. BRAKEPEDALADJUSTMENTS BrakePedal Height b See Figures 11, 12, and 13

/ \
Cir 44 rnca~urc .._^*I.- urime a*., 9.--l,- peoai nefgnr ar ---I-* L-@-L.-I rly. I I we A and compareto specifications

I I . .

Fig. 12 Adjustthe brake pedal height by in_-.L -*.a- creasmgor aecreasingthe lengrnor me operating rod

I I.

@57w I Fig. 13 *Inspect.the clearance between thf . ._ . .. _ .. mop llgnt WItCh arm the brake pedal stop and compareto specifications

\ \\

0.5-1.0 mm (.020-B40in.J I

BRAKES 9-5
Brakefluid containspolyglycol ethersand polyglycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If you do get brakefluid in your eyes, flush your eyes with clean, runningwa. ter for 15 minutes.If eye irritation persists, or if you havetaken brakefluid internally, IMMEDIATELY medical assistance. seek Inspect brake pedal free-play
firm that the amountof movementbeforeresistance is felt is within 0.1-0.3 in. (3-8mm). 3. If the free-playis lessthan desired,confirm thatthe brakelight switch is in properadjustment. 4. If thereis excessivefree-play,look for wearor play in the clevis pin and brakepedalarm. Replace worn partsas requiredand recheckbrakepedalfreePlay* 3. Removeand relocatethe air conditioningrelay box andthe solenoidvalve locatedat the power brakeunit. 4. Disconnect vacuumhosefrom the the boosterby pulling it straightoff. Pryingoff the vacuum hosecould damagethe checkvalve installedin the brakeboostervacuumhose. 5. Detachthe electricalharnessconnectorfrom the brakelevelsensor. 6. Removethe nutsattachingthe mastercylinderto the boosterand removethe mastercylinder and positionaside.If necessary, disconnect plug and the brakefluid lines at the mastercylinder. 7. From insidethe passenger compartment, removethe cotterpin and clevis pin that securesthe boosterpushrodto the brakepedal. 8. From insidethe vehicle,removethe nutsthat attachthe boosterto the dashpanel.Removethe brakeboosterfrom the enginecompartment. 10. Apply greaseto the clevis pin and install with washersin place.Install newcotterpin and bendto securein place. 11. Attachthe vacuumhoseto the boosterfitting. 12. Installthe mastercylinderassemblyto the mountingstudson the brakebooster.Installthe master cylindermountingnutsandtightento 9 ft. Ibs. (12 Nm). 13. Reconnect brakefluid reservoirto the the mastercylinder,if disconnected. Attachthe electrical connectorto the brakefluid levelsensor. 14. Installthe solenoidvalveassemblyandthe relaybox, if removed. 15. Connectthe negativebatterycable. 16. Add fluid to the brakefluid reservoiras required.

REMOVAL &INSTALLATION
b See Figure 15

'

Clean, high quality brakefluid is essentlalto the safe and properoperationof the brake system.Youshouldalways buythe highest quality brakefluid that is available. If the brakefluid becomescontaminated,drain and flush the system,then refill the mastercylinder with new fluid. Neverreuseany brake fluid. Any brakefluid that is removedfrom the systemshouldbe discarded.Also, do not allow any brakefluid to comein contactwith a paintedsurface;it will damagethe paint.
17. Bleedthe mastercylinder.If afterbleedingthe mastercylinderthe brakepedalfeelssoft, bleedthe brakesystemat all wheels. 18. Checkthe brakesystemfor properoperation. *

1. Disconnect negativebatterycable. the 2. Siphonthe brakefluid from the mastercylinder reservoir.

To install:
9. Installthe brakeboosterto the dashpanel. From insidethe vehicle,installthe attachingnutsand tightento 12 ft. Ibs. (17 Nm).

mr
l-13 t- I, Ltx5.

rn(

'13

5-18 NM

1. Relay box for air conditioner 2. Solenoid valve 3. Brake fluid level sensor connector 4. Brake tube 5. Master cylinder, hose and reservoir assem biy

Fitting 1 Cotter pin; Washer 1 Clevis pin

Fuel retuti tub8

installatiob bolt 12. Brake tUd8 installatioh bolt 13. Brake booster 14. Sealer
89579glt

Fig. 15 Explodedview of the power brake booster and related components-most models

9-6 BRAKES
REMOVAL INSTALLATION &
I) See Figure 2 1. Disconnect negative the battery cable. 2. Locate proportioning usually the valve, below themaster cylinder. 3. Taganddisconnect brake fromthe the lines valve. stiffbristle brush clean and brake fluid);besure to plugthelinesandports soonastheyareopened. as New andhoses lines should flushed with be clean brake before fluid installation remove contamito any nation. To install: 9. Install newlineor hose, the starting the with endfarthest themaster from cylinder. Connect the other then end, confirm both that fittings correctly are threaded turnsmoothly fingerpressure. and using Make thenewlinewill notrubagainst other sure any part.Brake must at least in.(13mm) lines be l/z from thesteering column other and moving Any parts. protective shielding insulators bereinstalled or must intheoriginal location.

REMOVAL&INSTALLATION
) See Figures16, 17, 18, and 19 1. Disconnect negative the battery cable. 2. Raise safely and support vehicle jackthe on stands. 3. Remove wheel tireassemblies any and necessary access theparticular youareremovfor to line ing. 4. Thoroughly thesurrounding atthe clean area jointsto bedisconnected. 5. Place suitable panunder jointto a catch the bedisconnected. 6. Using wrenches to holdthejoint two (one andonetoturnthefitting), disconnect hose the or lineto bereplaced. 7. Disconnect other of thelineor hose, the end moving drainpanif necessary. usea the Always back-up wrench avoid to damaging fitting. the 8. Disconnect retaining or brackets any clips holding lineandremove linefromthevehicle. the the -if the brakesystemis to remain openfor moretime than it takes to swap lines, tape or plug eachremainingclip and port to keep contaminants and fluid in. out

Brakefluid containspoiygiycoi ethersand poiygiycois. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. if you do get brakefluid in your eyes, flush your eyeswith clean, runningwater for 15 minutes.if eye irritation persists, or if you havetaken brakefluid internally, IMMEDIATELY medicalassistance. seek 4. Remove proportioning fromtheenthe valve ginecompartment. To install: 5. Theinstallation thereverse theremoval is of procedure. thebrakes thefollowing Bleed in order: 6. Diamante a. Right caliper rear b. Leftfrontcaliper c. Leftrearcaliper d. Right caliper front 7. Mirage and Gaiant a. Leftrearwheel cylinder caliper or b. Right cylinder front c. Right wheel rear cylinder caliper or d. Leftfrontcaliper 8. Connect negative the battery andcheck cable thebrakes proper for operation.

Makesure the hose is NOTkinkedor touching any part of the frame or suspensionafter installation. Theseconditionsmaycausethe hoseto fail prematurely. 10. Using wrenches before, two as tighten each fitting. Ii. Install retaining or brackets the any clips on lines. 12. If removed, thewheel tireasseminstall and blies, carefully thevehicle theground. then lower to 13. Refillthebrake master cylinder reservoir with clean, brake meeting 3 specificafresh fluid, DOT tions.Properly thebrake bleed system.

Clean, high quality brakefluid is essentialto the safe and properoperationof the brake system.Youshouldalways buythe highest

Clean, high quality brakefluid is essentialto the safe and properoperationof the brake system.Youshouldalways buythe highest quality brakefluid that is available. if the brakefluid becomescontaminated,drain and flush the system,then refill the mastercyiinder with new fluid. Neverreuse any brake fluid. Any brakefluid that is removedfrom the systemshouldbe discarded.Also, do not allow any brakefluid to comein contactwith a paintedsurface;it will damagethe paint.

tcca9p10
I

tcca9p09

Fig. 16 Use a brushto clean the fittings of any debris

Fig. 17 Usetwo wrenchesto loosen the fitting. If available, use flare nut type wrenches

Metallinesandrubber hoses brake should be checked frequently leaks external for and damage. Metallinesareparticularly to crushing prone and kinking under vehicle. such the Any deformation can restrict proper of fluidandtherefore the flow impair braking thewheels. at Rubber should hoses be checked cracking scraping; damage for or such can create weak inthehose it could under a spot and fail pressure. Anytimethelinesareremoved disconnected, or extreme cleanliness beobserved. all must Clean jointsandconnections disassembly a before (use

tcca9pll

Fig. 18 Any gaskets/crushwashers should be replaced with new ones during instaiiation

tcca9p12

Fig.19Tape or plug the line to prevent contamination

BRAKES 9-7

b See Figures 20 thru 28 When partofthehydraulic any system been has disconnected repair replacement,mayget for or air intothelinesandcause spongy action pedal (because canbecompressed brake cannot). air and fluid Tocorrect condition, is necessary bleed this it to the hydraulic system to besureall air is purged. so When bleeding brake the system, onebrake bleed cylinder atime,beginning thecylinder the at at with longest hydraulic (farthest themaster line from cylinder)first.ALWAYS themaster keep cylinder reservoir filledwithbrake during bleeding fluid the operation, Never brake thathasbeen use fluid drained the from hydraulic system, matter clean is. no how it Theprimary secondary and hydraulic sysbrake terns separate arebledindependently. are and During thebleeding operation, notallowthereservoir do to rundry.Keep master the cylinder reservoir with filled brake fluid. 1. Clean dirtfromaround master all the cylinder fill cap,remove capandfill themaster the cylinder withbrake untilthelevelis withinV4in.(6mm) fluid of thetopedge thereservoir. of

Fig. 22 Slawly crackopenthe bleederscrew

Fig. 28 Slowly open the bleed screw and

<Vehicles

with

A.&S.>

Fig, 23 The bleed screw for the rear brakes

91059p30

Fig. 20 Removethe bleeder screw cap

Fig, 27 Brake bleeding sequence-1993 Galant

Fig. 25 Attacha hose connectedto a bottle with a small amountof brake fluid in it to the bleed screw

9-8 BRAKES

1
2 3
93159g27

2, Clean bleeder the screws all 4 wheels. at The bleeder screws located theback thebrake are on of backing (drum plate brakes) onthetopof the and brake calipers brakes). (disc 3. Attach length rubber overthebleeder a of hose screw place other of thehose a glass and the end in jar,submergedbrake in fluid. 4. Open bleeder l/r3/4 turn.Have the screw an assistant slowlydepress brake the pedal.

or if you have taken brakefluid internally, IMMEDIATELY medicalassistance. seek 5. Close bleeder andtellyourassistant the screw to allowthebrake to return pedal slowly. Continue thisprocess purge airfromthesystem. to all 6. When bubbles to appear theendof cease at thebleeder close bleeder andremove hose, the screw thehose. Tighten bleeder to theproper the screw torque: 7. Check master the cylinder level add fluid and fluidaccordingly. thisafterbleeding wheel, Do each 8. Repeat bleeding the operation theremaining at 3 wheels, ending theonecloset themaster with to cylinder. 9. Fillthemaster cylinder reservoir theproper to level.

Fig. 28 Brake bleeding sequence-Mirage and Diamante

Brakefluid containspolyglycol ethersand poiygiycois. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. if you do get brakefluid in your eyes, flush your eyes with clean, runningwater for 15 minutes.if eye irritation persists,

# See Figures 29, 30, 31, and 32

REMOVAL &INSTALLATION

Olderbrake padsor shoesmay containasbestos,which has beendeterminedto be cancercausingagent. Neverclean the brake surfaceswith compressed Avoid inhaling air! any dustfrom any brake surface!When cieanlng brakesurfaces,use a commercially available brake cleaningfluid. Mirage and 1990-93 Gaiant *

FRONT @See Figure 33 1. Remove of thebrake fromthe some fluid master cylinder reservoir. reservoir The should no be more halffull.When pistons pressed than the are into thecalipers, excess will flowupintothereserfluid voir.
93159g23

I. ClDE PIN 2 LdcK Pm 3 WSHINO 4 CALIPER 9lJPwRT ,pM. cue sHYlcYaT : EiT Rim 7 PWON mm

8 mm 9 PlSToN SEAL 10 WPER BODY , 11 PmE~~yvEm INLKATclR 12 PAD As&&w ;: w&E SHlM ,

93159g28

Fig. 29 Front dual piston caliper exploded a view-Diamante

Fig. 30 Rear disc brake systemcomponent identification-1994-95 Galant

1. BRAKE HOSE CONNECTOR 2. GASKET 3. FRONT BRAKE ASSEMBLY 4. BRAKE DISC

BOLT

3 4 5 6 7 8 9

Rear brake ar?.embiy Rear Drake dnc Hubcap Wheel baanng tit Flew hub assemblv chlstshteki DISCbrake adapter

3 93159glC

1. 2. 3. 4.

Cons for the brake hose Gasket Front brake assembly Brake disc 93159911

93159g; !9

Fig. 31 FrontbrakesystemcomponentidenItification-1996-00 Gaiant

L

Fig. 32 Rear disc brake exploded view1996-92 Mirage

Fig. 33 Front disc brake components-Mirage

2. Raise vehicle support the and safely. 3. Remove appropriate andwheel the tire assemblies. 4. Remove calmer andlockDins the auide and lift thecaliper assemblyfrom caliper the support. Tie thecaliper of thewayusing 00 notallowthe out wire. caliper hang thebrake to by line. *On somevehicles, the caliper can be flipped up by leaving the upperpin in place and usinuit as a oivot ooint. ---sa - . -. 5. Remove brake spring and the pads, clip
cl7knr T&n 3 111,113.,(lhC nn+n ,-A nrdtinninntn ,,LC I p3Hy

11. Road thevehicle check test and brakes for proper operation. REAR u See Figures 32 and 34 * 1, Remove ofthebrake fromthe some fluid master cylinder reservoir. reservoir The should no be are more halffull.When pistons depressed than the intothecalioers. excess \n flowupintothe fluid /ill reservoir. 2. Raise vehicle support the and safely. 3. Remove appropriate andwheel the stire assemblies. 4. Loosen parking Ike the bra cable adjustment frominside vehicle. the 5. Disconnect parking cable inthe brake end stalled therearbrake to caliper assembly. 6. Remove caliper the lowerpinandswing the caliper assembly upwards. thecaliper ofthe Tie out wayusing wire. 7. Remove outer the shim, brake and . pads soring fromtlie caliper clips support. noteof Take nositibning eactto aidin installation. of I 8 IndalI twn . llluLull of thewheel nutsontothe L..V lug studs lightlytighten. is done holdthe and This to disconthehub. Cl Thrm-l the nictnn III1 r!alinar I., rlnrkhnre V. ,,,lV ,,,V ~,L,into thP ..*.prv, .-a. .IIV wiseusing brake toolMB9f52 its disc driver or equivalent. To install: 10. Lubricate sliding pivotpoints. all and 11. Install brake shims spring the pads, and clip to thecaliper support. 12. Install caliper oraxe---I~ the overme - paas.

*Be careful that the piston boot doesnot becomecaughtwhen lowering the caliper onto
+ha n,.nnnr) lh nnt t&at thm hr&a hnra rlnr-

13. Lubricate, andtighten lower install the pin. 14. Install tireandwheel the assemblies. Lower thevehicle. 15. Test brakes proper the for operation: Dlamanteand 1994-00 Galant k See Figures29,30,31,35 thru 47

I sir-4 inc+alhtinn a,u IIIaLcuIaLtII.

t i

6. Install wheel nuts thestuds two lug onto and lightlytighten. is done holdthedisconthe This to hub. To install: 7. Use large a C-clamp compress to piston(s) back caliper Ontwopiston into bore. calipers both pistons have beretracted will to together. 8. Lubricate points install brake slide and the pads, shims spring ont-+- --n-* n**nnnA and clip Install caliper thebrake the over ,..uuG. *Be careful that the piston boot does not becomecaughtwhen lowering the caliper onto the support.Do not twist the brakehose during caliper installation. 9. Lubricate install caliper and the guide and lockpinsin theiroriginal positions. Tighten the caliper guide locking and pins. 10. Install tireandwheel the assemblies. Lower thevehicle. *Pump the brakepedal several times, until firm, before attemptingto movethe vehicle.

Brakepadsandshoescontainasbestos, which has beendeterminedto be a cancer causingagent. Neverclean the brakesurfaces with compressed Avoid inhaling air! any dustfrom brakesurfaces!Whencleaning brakes.use commerciallvavallable brake cleaningflutds. *Unlike most rear disc brakedesigns,this systemdoesnot incorporatethe parking brakesystem, into the rear brakecaliper, therefore, the rear brakesystemis serviced the sameas the front system. 1. Remove of thebrake fromthe some fluid master cylinder reservoir. reservoir The should no be more r/afull.When pistons depressed than the are intothecalipers, excess will flowupintothe fluid reservoir.

93159#2

Fig. 34 Retracting brake caliper piston and aligning pad to piston-hlirage

Fig. 35 Use mechanics wire or a similar device to supportthe caliper out of the way

Fig. 36 Remove the inner brake pad and ...

93159p33

Fig, 37 . . . also the outer pad from the caliper

Fig. 38 Removethe spring clips and replace if necessary

Fig. 39 Thecaliper piston can be depressed using a special tool, such as this one from Lisle@or . . .

9-10 BRAKES

Fig. 40 . . . a large C-clampwill also work to compressthe caliper piston

then makesure to lubricate the

IO. Lubricate install caliper and the guide and lockpinsintheiroriginal positions. 11. Tighten guide locking to 54ft. the and pins Ibs.(75Nm)onthefront,and20ft. Ibs.(27Nm)on therear, 12. install tireandwheel the assemblies. 13. Lower vehicle. the

Pumpbrake pedalseveral tlmes, until firm, before attemptingto movevehicle. Fig. 47 Apply more brakequiet over the outwdeof the shambefore installing the pads /, the vehicle .Is/l* 5. Remove brake spring and the pads, clip shims. noteof positioning aidinstallation. Take to the lug and 6. Install wheel nutsontothestuds lightlytighten. is done holdthedisconthe This to hub. To install: a C-clamp compress pisto the 7. Use large ton(s)back caliper into bore. _ slide and the 8. Lubricate points install brake pads, shims spring ontothecaliper and clip support. the over pads. 9. Install caliper thebrake *Be careful that the piston boot does benot comecaughtwhen lowering the caliper onto the support.Do not twist the brake hoseduring caliper installation. 14. Road thevehicle check test and brakes for proper operation. INSPECTION p See Figures 48 and 49

Fig. 46 . . . then install the shim on the pads 2. Raise vehicle support the and safely. 3. Remove appropriate andwheel the tire assemblies. 4. Remove caliper the guide lockpinsand and lift thecaliper assembly thecaliper from support. Tie thecaliper of thewayusing out wire. (I Do not allow the caliper to hangby the brake line. *On somevehicles, the caliper can be flipped up by leaving the upperpin in place and using it as a pivot point.

Olderbrakepadsor shoesmay containasbestos,which has beendeterminedto be cancercausingagent. Neverclean the brake surfaces compressed Avoid inhaling with air! anydustfrom any brakesurface! When cleaningbrake surfaces,usea commercially available brake cleaningfluid. Thediscbrake have indicators pads wear that contact brake when brake thickness the disc the pad becomes in.(2.0mm) emita squealing 0.08 and sound wornthedriver. to

BRAK& 9-11
1, Disconnect battery the negative cable. 2. Raise vehicle support the and safely. 3. Remove appropriate andwheel the tire as---L,:-SeIIIUIIM. 4. Loosen parking cable the brake adjustment frominside vehicle. the 5. Remove retaining anddisconnect the clips, theparking cable therearbrake brake from caliper assembly. rflo not let ali into the mastercylinder by allowing the reservoir to emptyor complete systembleedingwill be required. 6. OnFWD models, disconnect brake to the nose mecanoer. rrom remove oamo nomme me DOII brake caliper. 7. OnAWD models, thenutonthebrake hold hose andloosen flared side the brake nut.With line thehose disconnected line,remove brake atthe the hose thecaliper. from 8. Remove caliper pin.Pivot caliper the lock the upward, slidethecaliper and assembly the from caliper support. To install: 9. OnFWD models, therearbrake install hose ontothecaliper new with washers place in and tighten brake retainer. the hose 10. OnAWD models, connect brake to the hose thecaliper tighten fittingto 9-12ft. Ibs. and the (13-17Nm). connect hose thebracket Then the at to thesteellineandtighten fittingto 9-12ft. Ibs. the (13-17Nm). rDo not twist the brakehoseduringinstallatlon. 11. Install caliper thebrake making the over pads, surestopper linesupwithpadprojection. grove 12. Lubricate install lockpinandtighten and the to 23ft. tbs.(32Nm). 13. Bleed brake the system. 14. Inspect brake the system leaks ensure for and proper operation. 15. Install andwheel tire assemblies. 16. Properly adjust parking cable. brake Diamanteand 1994-08 Galant 8 See Ffgures50 thN 55 Unlike reardiscbrake most designs, system this does incorporate parking system not the brake into therearbrake caliper. Therefore, rearbrake the systemis serviced same thefrontsystem. the as

B957wJ

FIQ. 48 Inspect front disc pad thickness through caliper body check port

BrakepadsanIdshoescontalnasbestos, !n which has bee determinedto be a cancer causingagent. Neverclean the brakeSUP npressedair! Avoid inhaling faces with con any dustfmm brakesurfaces!Whencleaning brakes,use cflmmercially available brake cleaningfluid c Mirage and 199Q-93Galant

Inspect thickness thebrake the of linings lookby ingthrough brake the caliper check The body port. standard of thebrake is 0.39in.(1Omm). value pad Thethickness of theliningis0.08in.(2.0mm). limit When limitisexceeded, the replace pads the on bothsides thebrake andalsothebrake of disc pads onthewheel theopposite ofthevehicle. on side Do notreplace padona caliper 1 because wear the indicatoris hitting, without replacing other onthe the pad same wheel wellasthebrake ontheother as pads frontor rear wheel, applicable. as If there a significant is difference thethickness in ofthepads theleftandrightsides, on check slidthe IDCk and ingcondition thepiston, pinsleeve guide of pinsleeve.

*Do not let air into the mastercylinder by allowing the reservoir to emptyor complete systembleedingwill be required. 3. Todisconnect frontbrake holdthe the hose, nutonthebrake sideandloosen flared hose the brake nut.With hose line the disconnected line, atthe remove brake fromthecaliper. the hose 4. RfXIIDVethecaliper guide lockpins. and 5. Remove caliper the assembly thecaliper from support. To install: 6. Position brake the caliper thecaliper onto
SUppOrt.

7. Install tighten guide lockpins. and the and 8. Reconnect brake the hose. *Use caution not to twist brakehose during installation. 9. Bleed brake the system. 10. Apply brake andinspect system pedal the for proper operation noleakage. and 11. Install andwheel tire assembly. REAR Q See Figure 17

FiQ.50 The brake caliper is mountedto the eaiiper supportwith two bolts

support retaining bolts

Fig. 52 Graspthe caliper and Ilft it from the caliper assemblyfrom the caliper support

942

BRAKES

Fig, 53 Loosenthe caliper hose banjo bolt

. *.

93155~46 I 1Fig. 54 . . , then remove the bolt from the fitting

1Fig. 55 Make sure that you removethe copper washers and replace them with new ones during reassembly *Some vehicles may be equippeddual piston calipers. The procedureto overhaulthe caliper is essentiallythe samewith the exceptionof multiple pistons,D-ringsanddust boots. 1. Remove caliper thevehicle the from and place a clean on workbench.

1I Raise vehicle support the and safely. 2. Remove appropriate andwheel the tire assembly. *Do not allow the mastercylinder reservoir to empty.An emptyreservoir will allow air to enter the entire brakesystemand complete systembleedingwill be required. 3. Todisconnect brake onmodels the hose with a banjo-bolt connecting brake to thecaliper the hose assembly, remove boltatthehose simply the connection. disconnect brake onall other To the hose systems, thenutonthebrake sideand hold hose loosen flared the brake nut. line

7. Install guide andlockpin.Tighten the pin to 23ft. Ibs.(32Nm). 8. Reconnect brake of install banjo the hose the boltwithnew washers. *Use caution not to twist the brake hose during installation. 9. Bleed brake the system.

Brakefluid containspolyglycol ethersand poly~lycols. Avoid contactwith the eves and wash your handsthoroughlyafter handling brakefluid. if you do get brakefluid In your eyes, flush your eyes with clean, runningwater for 15 minutes.If eye irritation persists, or if you havetaken brakefluid internally, IMMEDIATELY medicalassistance. seek 4. Once hose been the has disconnected from theline,remove brake fromthecaliper, the hose 5. Remove caliper the guide lockpinsand and lift thecaliper assembly thecaliper from support, To install: 6. Position caliper thecaliper the onto support.

Clean,high quality brakefluid is essentialto the safe and proper operationof the brake system.Youshouldalways buy the highest quality brakefluid that is available. If the brakefluid becomescontaminated,drain and flush the system,then refill the mastercylinder with new fluid. Never reuseany brake fluid. Anvbrakefluid that is removedfrom the systumshouldbe discarded.Also, do not allow any brakefluid to comein contactwith a paintedsurface; it will damagethe paint. 10. Apply brake andinspect system pedal the for leaks. Ensure proper operation noleakage. and 11. Install andwheel tire assembly. Torque lug nuts 87-101 Ibs.(120-140 to ft. Nm).

NEVER place your fingers in front of the pistons in an attemptto catchor protectthe pistons when applyingcompressed This air. could result in personalinjury! *Depending uponthe vehicle, there are two different waysto removethe pistonfrom the caliper. Referto the brake padreplacement procedureto makesure you havethe correct procedurefor your vehicle. 2. Thefirstmethod asfollows: is a. Stuffa shoptowelor a blockof woodinto thecaliper catch piston. to the b. Remove caliper the piston usingcompressed applied thecaliper hole.Inair into inlet spect piston scoring, the for nicks, corrosion and/or or damaged worn chrome plating. The piston bereplaced anyof these must if conditionsarefound.

OVERHAUL
b See Figures56 thru 63

BRAKiS 9-13

Fig. 59 Use a prytool to carefully pry around1 the edge of the boot , , .

caiper housing,taking care not to score or 1 damagethe bore

ing the piston seal; DO NOT scratch the 15. Use suitable a driving to seat bootsin tool the thehousing. 16. Install caliper thevehicle. the in 17. Install wheel tireassembly, carethe and then fullylower vehicle. the 18. Properly thebrake bleed system.

REMOVAL &INSTALLATION

Fig. 62 Usethe proper size driving tool and a mallet to properly seal the boots in the calmer housino . --~-~~~v 3. Forthesecond method, must you rotate the piston retract fromthecaliper. to it 4. If equipped, remove anti-rattle the clip. 5. Use prytool remove caliper bea to the boot, ingcareful to scratch housing not the bore. 6. Remove piston fromthegroove the seals in thecaliper bore. 7. Carefully loosen brake the bleeder cap valve
~nrl .UIY lllll Yll \I~IWJ frnm the r~linor LIIb rro,spl hnlwinn tIJlly.

Fig. 63 Thereare tools, suchas this MightyVat, available to assist in proper brakesys1 tam -.---...= hlasrlinn --...

I 9. Use crocus to polish lightcorrosion cloth out fromthepiston bore. and 10. Clean parts denatured all with alcohol and drywithcompressed air. To assemble: and the valve 11. Lubricate install bleeder and NP. 12. Install newseals thecaliper the into bore
mlr;nn

Brakepadsand shoescontainasbestos, which has beendeterminedto be a cancer LL..... rlrr.. .I.,. l.uLr I.. causinaaaent. I.twla lilci(lll Lllli uranl$ au,faces with-compressed Avoid Inhaling air! any dustfrom brakesurfaces!Whencleaning brakes, usecommerciallyavailable brake cleaningfluids. 1993-09 Mirage, Diamante,and Galant 6 See Figures64 thru 70 Thefollowing procedureapplicable boththe is to frontandrearbrakes. 1. Raise vehicle support the and safely. 2. Remove appropriate the wheel. 3. Remove caliper brake the and pads.

nrnnlrhr ytvvvca,

lllanllly

Clln-.

3IC M..-.., ale n.4 h..~ o,ey nrn II, IWI~LCL.

8. Inspect caliper the bores, pistons mountand ingthreads scoring excessive for or wear,

13. Lubricate piston the bore. the and into of 14. Install pistons boots thebores thecalipers push thebottom thebores. and to of

Fia. 64 Suoaarl the calmer usina me., -----=-..chanicswire or anothersuitable device, Do NOTlet it hang by the brake hose

Fig. 65 Removethe caliper bracket retaining bolts . . .

Fig. 66 m . then removethe caliper bracket . from the vehicle

9-14 BRAKES

two threaded hoks to-

Fig. 68 tnstatt a suitable size bolt into the threadedholes

Fig. 69 Tightenthe bolts until they force the rotor off of the hub . . .

1hub assembly 4. Support caliper of thewayusing wire. the out a 5. Onsome models rote is held thehub the )r to bytwosmall threaded screws. Remove screws the
.mrl ml n,,ll p nff II thn rntnr crw lLl.

To install: 6. Position rotoronthehubandinstall the the mounting screws. 7. Install caliper the holder brake and pads. 8. Slide caliper thebrake and the over pads tighten guide the pins. 9. Install wheel tighten lugnuts. the and the

Pumpthe brake pedalseveral times before attemptingto movevehicle.

6. Remove brake the pads. 7. the ., 3 Remove balljointandtierodendfrom melower control arm. 8. Use puller push halfshaft and to the through therotor/hub assembly. 9. Remove lower boltsandremove the strut the asseml fromthevehicle. bly 10. Toseparate rotorfromthehubassembly, the remove rotorretainer andseparate the bolts using toolMB991001 equivalent. or To Install: 11. Assemble rotorandhub. the Tighten nuts the to 40ft. Ibs.(54Nm) install assembly the and the to venae. 12. Install washer thechamfered the so edge faces outward. thenutandtighten Install temporarily. 13. Install balljointandtie rodend. the 14. Install brake the components. 15. Install wheel lower vehiclk the the and the to floor.

sallluly.

To install: 7. Position rotoronthehub.Install couple the a of lugnuts lightlytighten holdrotoronhub. and to 8. Install caliper the holder place and brake pads holder. in 9. Slidecaliper brake I>a,I II13m11 over paAl- inr+*.rli --,I YI, the can guide Once pins. caliper secure1 lugnuts is mmnmrl hoIUIII. U 10. Reconnect parking cable install brake and wheel(s).

INSPECTION
measure at .I Using micrometer, 43 thediscthickness LL- a eignr *.* approxlmarelyaegrees 1ana posmons, apan I 0.39in.(10mm) fromtheouter of thedisc. in edge Theminimum thickness 0.882 (22.4mm) is in. for frontrotors 0.331 (8.4mm), a maximum or in. with thickness variation 0.0006 (0.015mm). of in. If thediscis beyond forthickness, limits remove it andinstall newone.If thethickness a variation exceeds specifications, thediscor turnrotor the replace withonthecartypebrake lathe.

I \ _,

.I.

BRAKis 9-15

9-16 BRAKES
REMOVAL&INSTALLATION 1. Raise safely and support vehicle. the 2. Remove rear the wheel. 3. Loosen parking adjusting the brake nut. 4. Pullthedrum therearhubassembly. from Tap thedrum a softmallet necessary. with if To install: 5. Install drum therearhubassembly. the on 6. Install wheel adjust parking the and the brake. 7. Lower vehicle thefloor. the to 'INSPECTION b See Figure 76 \ INSPECTION u See Figure 77

Brakepadsand shoescontain asbestos, which has beendeterminedto be a cancer causingagent. Neverclean the brake surfaces with compressed Avoid inhaling air! any dustfrom brakesurfaces!Whencleaning brakes, use commerciallyavailable brake cleaningfluids. 1996-92 Mirage $ See Figure 71 1. Raise vehicle support the and safely. 2. Remove wheel tireassembly. the and 3. Remove dustcap. the 4. Remove self-locking the nut. 5.. Remove outer the wheel bearing. 6. Remove drum theinner the with wheel bear- ingfromthespindle. 7. Remove grease the seal. To install: 8. Todeterminetheself-locking is if nut reusable: a. Screw theself-locking untilabout in nut l/e in.(3mm) thespindle showing. of is b. Measure torque the required turnthe to self-locking counterclockwise. nut c. Thelowest allowable torque 48 inchIbs. is (5.5Nm).If themeasured is lessthanthe torque specification, replace nut. the 9. Lubricate install inner and the wheel bearing. 10. Install newgrease a seal. 11. Install drum thespindle. the to 12. Lubricate install outer and the wheel bearing. 13. Tighten self-locking to 108-145 the nut ft. Ibs.(150-200 Nm). 14. Install grease the cap. Galantand 1993-90 Mirage b See Figures72, 73, 74, and 75

1. With brake removed thevehicle, the drum from measure inside the diameter thehubanddrum of at twoor more locations. 2. Theservice specification9.1in. limit is (231mm). 3. Replace brake the drums shoe lining and and assemblies thewear when exceeds limitor is the badly of balance. out

Brakepadsandshoescontainasbestos, which has beendeterminedto be a cancer causingagent. Never clean the brakesurfaces with compressed Avoid inhaling air! any dustfrom brakesurfaces!Whencleaning brakes,usecommerciallyavailable brake cleaningfluids. \ 1. Remove brake the drum. 2. Measure wear thebrake atthe the of lining place themost. service for replaceworn The limit ment 0.039 (1.Omm). is in.

Fig. 76 Measurathe inside diameter of the brake drum

,BRAKiS 9-17
*When servicing drumbrakes,only dissemble and assembleone side at a time, leaving the remainingside intact for reference. 3. Replace shoe lininqassembly any the and is located lessthan limit.Wh&ever is the theshoe and liningassembly replaced, sureto replace is be the leftandrightsideassemblies a setto prevent as the carfrompulling onesidewhen to braking. 4. If there a bigdifference is between thickthe ness theshoe liningassembly theleftand of and on rightsides, check slidingcondition thewheel the of cylinder piston. 1. Raise vehicle support and safely. 2. Remove tireandwheel the assembly. *Note the location of all springsandclips for properreassembly. 3. Remove brake the drum. 4. Remove frontshoe-to-rear spring. the shoe 5. Remove shoe-to-lever andremove the spring theadjuster assembly. 6. Remove shoe the hold-down andthe clips brake shoes. 7. Disconnect parking cable the the brake from
m-r ehnnc hu .rnmoAinn t$e horseshoe clip apa&

Galantand 1993-00 Mirage I See Figures 78 thru 93 1. Raise safely and support vehicle. the 2. Remove rear the wheels drums. and 3. Remove leverreturn the spring. 4. Remove shoe-to-lever the spring. 5. Remove adjuster the lever. 6. Remove auto-adjuster the assembly. 7. Remove retainer the spring. 8. Remove brake hold-down the shoe springs Bnd spring cups. 9. Remove shoe-to-shoe the spring. 10. Remove brake the shoes. 11. Disconnect parking cable the the brake from everontherear shoe. To install: 12. Remove parking lever theuse1 the brake from shoe installit onthenewbrake Make and shoe. sure hewave washer installed theproper is in direction. 13. Clean backing andlightlyapply the plate Irake grease thesixshoe to support pads. 14. Clean adjuster the assembly applybrake and grease thethreads; notusemore to do grease than iecessary. 15. Connect parking cable thelever the brake to In therear shoe. 16. Position rear onthebacking the shoe plate nd install hold-down the spring pin. and 17. Position frontshoe thebacking the on plate indinstall hold-down the spring pin. and 18. Position adjuster the assembly between the woshoes. 19. Install shoe-to-shoe the spring.

REMOVAL &INSTALLATION
1990-92 Mirage ti See Figure 71

Brakeshoescontainasbestos,which has beendeterminedto be a cancercausing agent. Neverclean the brakesurfaceswith compressed Avoid inhaling any dustfrom air! brakesurfaces!Whencleanina brakes. use commerciallyavailable brakeileaning fluids.

To install: 8. Thoroughly anddrythebacking clean plate. Ensure backing bosses smooth, the plate are so shoes bind. wont 9. Lubricate backing bosses, plate anchor pin, andparking actuating brake mechanism a with lithium-based grease. 10. Remove, anddryall remaining clean parts. Apply anti-seize thestarwheel to threads transfer and all parts thenewshoes. to 11. Connect parking armto theapprothe brake priate brake shoe. 12. Attach to thebacking andinstall shoes plate all remaining hardware thereverse it wasrein order moved. 13. Preadjust shoes thedrum the so slides on witha lightdrag installbrake and drum. 14. Install new a wheel bearinq self-lockinq nut to andtorque 130ft. Ibs.(180Nmj. 15. Install wheel the bearing capandadjust dust ie rearbrake shoes.

89579pc4

8 Rear drum brake components-

Fig. 79 Use a pair of pliers or a special brake tool to remove the shoe-to-lever spring ,

89579po5

Fig. 80 Removethe adjuster lever assembly

93155Qlcl

Fig. 81 Removethe auto adjuster assembly1

Fig. 82 Remove the lower brake shoe retaining spring

Fig. 83 Using a suitable hold-down spring tool, compress the hold-down spring and

..

If

--I,..,,..

9-18 BRAKES

Fig. 84 . . . remove the hold-down spring and cup assembly

Fig. 85 With the shoes attached by the spring, pull them apart to clear the hub and bearing . . .

then detachthe parkin cable andremovethe shoe and Knin

895791139 93159pzz

9315955

Fig. 90 Apply a high temp lubricant to the shoe contact points on the backingplate

Fig. 91 Proper installation of the wave washer 20. Install retainer the spring. +21.Install adjuster the lever. 22. Install shoe-to-lever the spring. 23. Install lever the return spring. 24. Adjust brake the shoes install drum. and the 25. Install wheel tireassembly. the and 26. Lower vehicle thefloor. the to ADJUSTMENTS Therearbrakes automatically are adjusted while driving vehicle. brakes alsoadjusted the The are each timetheparking is applied. brake Manual adbrake justment onlyrequired thebrake is after shoes or

Fig. 92 A portable cleaning tub madeespecially for cleaning brakes, like this one from SafetyKleen@, extremely helpful is hardware been has replaced, theadjuster been or has replaced. 1. Remove brake asdescribed this the drum in section. 2. Remove excessive anddirtpresent any dust on thebrakes theappropriate using methods. 3. Using brake a adjustment measure gauge, the inside diameter thebrake of drum. 4. Adjust brake the shoes thesame to diameter as thedrum placing brake by the adjustment on gauge theshoes turntheadjusting wheel. and star 5. install brake asdescribed thissecthe drum in tion. L

Fig. 93 If a cleaning tub is not available, a quality aerosol cleaning solvent can be

BRAtiES9-19
REMOVAL&INSTALLATION \
u See Figures94, 95, 98, 97, and 98 1. Safely andsupport vehicle. raise the 2. Remove rearwheel thedrum. the and 3. Remove spring theadjuster the on lever, 4. Remove shoe-to-shoe the spring. 5. Remove autoadjuster the assembly. *Soecial flare nut wrenchesshauldbe used 7. Remove wheel the cylinder mounting bolts andthewheel cylinder. To install: 8. Install wheel the cylinder thebacking on plate. Tighten mounting to 7 ft. Ibs.(10 the bolts Nm). 9. Connect brake thewheel the line cylinder. Tighten linefittingto 11ft. Ibs.(15Nm). the 10. Addbrake tothereservoir leave fluid and the wheel cylinder bleeder loose. screw Brake will fluid start flowintothewheel the cylinder may and save timewhen bleeding brake the system later. 11. Install autoadjusterassembly. the

OVERHAUL
u See Figures 99 thru lD8 Wheel cylinder overhaul maybeavailable, kits but often littleor nosavings a reconditioned at over wheel cvlinder. often It makes withthese sense components substitutenewor reconditioned into a part stead attempting overhaul. of an If noreplacement isavailable, youwouldprefer or to overhaul wheel your cylinders, following the procedure beused. may When rebuilding installing and wheel cylinders, getting contaminants avoid any into thesystem. Always clean, highquality use new, brake fluid.If dirtyor improper hasbeen it will fluid used, benecessarydraintheentire to system, the flush system proper fluid,replace rubber with brake all components, refillandbleed system. then the

Fig. 97 The wheel cylinder is held by two retaining bolts; remove the bolts . . .

Fig. 98 . . . then removethe wheel cylinder from the backingplate

Fig. 99 Remove the outer boots from the

Fig 100 Compressed can be usedtoreair / movethe pistons and seals Tr 1

Fig 102 Use brakefluid and a sofl brushto /cleanthepistons. . *I6

9-20 ,BRAKES
1. Remove wheel the cylinder thevehicle from andplace a clean on workbench. 2. Firstremove discard oldrubber and the boots, withdraw pistons. then the Piston cylinders are equipped seals a spring with and assembly, loall cated behind pistons thecylinder the in bore. 3. Remove remaining components, the inner seals spring and assembly. Compressedmay air be useful removing components. comin these If no pressed is available, VERY air be careful to score not thewheel cylinder when bore removing fromit. parts Discard components which all for replacements were supplied therebuild in kit. 4. Wash cylinder metal in denathe and parts tured alcohol clean fluid. or brake 5. Allowtheparts air dryor usecompressed to air.Donotuserags cleaning, lintwill refor since main thecylinder in bore. 6. Inspect piston replace if it shows the and it scratches. 7. Lubricate cylinder andseals the bore using clean fluid. brake 8. Position spring the assembly. 9. Install inner the seals, thepistons. then IO. Insert newboots thecounterbores the into bv hand. notlubricate boots, Do the 11, Install wheel the cylinder,

Neveruse a mineral-basedsolvent suchas gasoline, keroseneor paint thinnerfor cleaning purposes.Thesesolventswill swell rubber components quickly deteriorate and them.

m9017

Fig. 103. . . andthe bore of the wheel cylin-

der

1Fig. 104 Oncecleaned and inspected, the 1wheel cylinder Is ready for assembly

-9P20
Fig. 106 Install the spring, then the cup seals in the bore Fig 107 Lightly lubricate the pistons z 1install them Fig. 108 The boots can now be instaT: over the wheel cylinder ends

REMOVAL& INSTALLATION
Mirage WITHREARDRUMBRAKES -If equippedwitti an air bag(SRSsystem), be sure to disarmsystembefok starting rdaairs on the vehicle. 1. Disconnect negative the battery cable. 2. Remove screws thecenter the from section andremove rearpartof theconsole. the *If equippedwith SRS,when removingthe floor console, dontallow any impactor shockto the SRSdiagnosticunit.

3. Remove rear cushion. the seat 4. Remove center clamp grommet. the cable and 5. Raise vehicle support the and safely. 6. Attherear wheel, remove brake and the drum shoes. 7. Disconnect cable fromtheparking the end brake lever. strut 8. Compress retaining to remove the strips the cable thebacking from plate. 9. Unfasten other any frame retainers reand move cables. the To install: 10. Theparkinq cables becolorcoded brake mav to indicate Check parking cables stde. the brake for anidentification mark. 11. Install cable therear the to actuator. Secure in place theparking cable andretainer with brake clip spring. 12. Install brake the shoes drum. and

13. Position cable loosely the and install rethe tainers. 14. Reattach parking cables theactuthe brake to atorinside vehicle. the 15. Adjust rearbrake the shoes. 16. Tighten adjusting untiltheproper the nut tensionis placed thecable. on Adjust parking the brake stroke using appropriate method. 17. Secure cable all retainers, 18. Apply release parking a number and the brake of times all adjustments been once have made. 19. With rear the wheels raised, sure make the oarkino is notcausina brake excess .A therear draaon wheels: 20. Install floorconsoleand seat the rear assembly. 21. Connect negative the battery cable. 22. Check theparking holds vehithat brake the cleonanincline.

9-21 BRAKES
WITH REAR DISC BRAKES

*If equippedwith an air bag(SRSsystem), be sure to disarmthe systembeforestarting repairs on the vehicle.
1. Disconnect negativebatterycable. the 2. Removethe screwsfrom the centersection and removethe rearpart of the console.

*If equippedwith SRS,when removingthe floor console, dont allow any impactor shockto the SRSdiagnosticunit.
3. Removethe rearseatcushion. 4. Loosenthe cableadjustingnut and disconnectthe rearbrakecablesfrom the actuator. 5. Removethe centercableclampand grommet. 6. Raisethe vehicleand supportsafely. 7. Removethe parkingbrakecableclip and retainerspring. 8. Disconnect cableend from the parking the brakeassembly. 9. Unfasten remainingframeretainersand any removethe cablesfrom the vehicle.

h. Removethe consoleassemblyfrom the vehicle. 3. While pressingdownwardon the front of the rearseatcushion,releasethe locking leversand removethe seatcushion. 4. Loosenthe cableadjustment the cable at equalizer. 5. Removethe centercableclampand grommet. 6. Raisethe vehicleand supportsafely. 7. At the rearwheel,removethe brakedrum and shoes. 8. Disconnectthe cableendfrom the parking brakestrut lever. 9. Removethe snapringsecuringthe cableto the backingplate. IO. Unfasten otherframeretainersand reany movethe cables.

7. At the rearcaliperassembly,removethe parkingbrakecableclip and retainerspring. 8. Disconnect cableendfrom the caliper. the 9. Unfasten remainingframeretainersand any removethe cablesfrom the vehicle.

To install: *The parkingbrake cablesmay be color codedto indicateside. Checkthe parking brake cablesfor an identification mark.
IO. Connectthe cableto the actuatorat the brake caliper.Securein placewith the parkingbrakecable clip and retainerspring. 11. Positionthe cableand looselyinstallthe retainers. 12. Reattach parkingbrakecablesto the actuthe ator insidethe vehicle.Tightenthe adjustingnut until the propertensionis placedon the cable. 13. Adjustthe parkingbrakestrokeusingappropriatemethod. 14. Secureall cableretainers. 15. Apply and releasethe parkingbrakea number of times onceall adjustments havebeenmade. 16. With the rearwheelsraised,makesurethe parkingbrakeis not causingexcessdrag on the rear wheels. 17. Installthe floor consoleassemblyand rear seatcushion. 18. Connectthe negativebatterycable. 19. Checkconsoleelectricalcomponents for properoperation. 20. Roadtestthe vehicleand checkfor proper brakeoperation. 21. Checkthat the parkingbrakeholdsthe vehicle on an incline.

To install: *The parkingbrakecables may be color codedto indicateside. Checkthe parking brake cablesfor an identification mark.
11. Installthe cableto the rearactuator.Securein placewith the parkingbrakecableclip andsnapring. 12. Installthe brakeshoesand drum. 13. Positionthe cableand looselyinstallthe retainers 14. Reattach parkingbrakecablesto the actuthe ator insidethe vehicle.Tightenthe adjustingnut until the propertensionis placedon the cable.Adjustthe parkingbrakestrokeusingappropriatemethod. 15. Secureall cableretainers. 16. Apply and releasethe parkingbrakea number of times onceall adjustments havebeenmade. 17. Adjustthe rearbrakesand parkingbrakecables. 18. Checktherear wheelsto confirmthatthe rear brakesare not dragging. 19. Installthe centerconsoleand rearseatcushion. 20. Connectthe negativebatterycable. 21. Checkconsoleelectricalcomponents for properoperation. 22. Checkthatthe parkingbrakeholdsthe vehicle on an incline. WITH REAR DISC BRAKES 1. Disconnectthe negativebatterycable. 2. Removethe centerconsoleas follows: a. Removeboth side cover panels. b. Removethe shifter knob on manual transaxlemodels.Removethe spacertrim piece on automatictransaxlemodels. c. Removethe switch panel/boxand remove the two screwsbeneath panel/box. the d. Removethe radio trim panel. e. Removethe radio and tape player. f. Removethe console inner paneland remove the two screwsfrom beneaththe panel. g. Removethe remainingscrewsfrom the sides of the console. h. Removethe consoleassemblyfrom the vehicle. 3. While pressingdownwardon the front of the rearseatcushion,release locking leversand rethe movethe seatcushion. 4. Loosenthe cableadjustingnut and disconnectthe rearbrakecablesfrom the actuator. 5. Removethe centercableclampand grommet. 6. Raisethe vehicleand supportit safely.

To install:
IO. The parkingbrakecablesmay becolor coded to indicateside. Checkthe parkingbrakecablesfor an identificationmark. 11. Installthe cableto the rearactuator.Securein placewith the parkingbrakecableclip and retainer spring. 12. Positionthe cableand looselyinstall the retainers. 13. Reattach parkingbrakecablesto the actuthe ator insidethe vehicle. 14. Tightenthe adjustingnut until the propertension is placedon the cable.Adjustthe parkingbrake . strokeusing appropriate method. 15. Secureall cableretainers. 16. Apply and releasethe parkingbrakea number of times onceall adjustments havebeenmade. 17. With the rearwheelsraised,makesurethe parkingbrakeis not causingexcessdrag on the rear wheels. 18. Installthe floor consoleand rearseatassembly. 19. Connectthe negativebatterycable. 20. Checkconsoleelectricalcomponents for properoperation. 21. Roadtestthe vehicleand checkfor proper brakeoperation. 22. Checkthat the parkingbrakeholds the vehicle on an incline.

1994-00 Galant
WITH REAR DRUM BRAKES 1. Disconnect negativebatterycable. the

The SRScontrol unit is mountedbeneaththe center console. Usecare when working with the centerconsoleassemblynot to impactor shockthe control unit.
2. Removethe centerfloor consoleassemblyas follows: a. Removethe shifter knob on models equippedwith a manualtransaxle. b. Removethe shifter trim panel. c. Removethe centerinstrumentpanel. d. Removethe panel box from the console assembly. e. Removethe two screwsfrom the centerof the console. f. Removethe four side panelscrewsand remove the consolefrom the vehicle. 3. Loosenthe cableadjusternut,then remove the parkingbrakecableby pulling it from the passenger compartment. 4. Raisethe vehicleand supportsafely. 5. At the rearwheel,removethe brakedrum and shoes. 6. Disconnect cableendfrom the parking the brakestrut lever.Compressthe retainingstrips to removethe cablefrom the backingplate.

1990-93 Galant
WITH REAR DRUM BRAKES 1. Disconnect negativebatterycable. the 2. Removethe centerconsoleas follows: a. Removeboth side cover panels. b. Removethe shifter knob on manual transaxlemodels.Removethe spacertrim piece on automatictransaxlemodels. c. Removethe switch panel/boxand remove the two screwsbeneaththe panel/box. d. Removethe radio trim panel. e. Removethe radio and tape player. f. Removethe console inner paneland remove the two screwsfor beneaththe panel. g. Removethe remainingscrewsfrom the sides of the console.

--7 9-22 BRAKES

7. Unfasten otherframeretainersand reany movethe cables.

To install:
8. Installthe cableto the rearactuator.Securein placewith the parkingbrakecableclip and retainer spring. 9. Installthe brakeshoesand drum. 10. Positionthe cableand looselyinstallthe retainers. Il. Reattach parkingbrakecablesto the actuthe ator insidethe vehicle. 12. Tightenthe adjustingnut until the propertension is placedon the cable. 13. Adjust the parkingbrakestrokeusingappropriatemethod. 14. Secureall cableretainers.Apply and release the parkingbrakea numberof times onceall adjustmentshavebeenmade. 15. Assemblethe interior components which wereremoved. 16. Adjustthe rearbrakesand parkingbrakecables. 17. Connectthe negativebatterycable. 18. Checkthe rearwheelsto confirmthatthe rear brakesare not dragging. 19. Checkthat the parkingbrakeholdsthe vehicle on an incline. WITH REAR DISC BRAKES

b. Removethe shifter trim panel. c. Removethe centerinstrumentpanel. d. Removethe panelbox from the console assembly. e. Removethe two screwsfrom the centerof the console. f. Removethe four side panel screwsand red move the consolefrom the vehicle. 3. Loosenthe cableadjusternut,then remove the parkingbrakecableby pulling it from the passenger compartment. 4. Raisethe vehicleand supportsafely. 5. At the rearwheel,removethe brakecaliper and rotor. 6. Removethe parkingbrakeshoes.Referto the procedurein this section. 7. Disconnect cableendfrom the parking the brakestrut lever. 8. Compressthe retainingstrips to removethe cablefrom the backingplate. 9. Unfasten otherframeretainersand reany movethe cables.

c. Removethe four side panelscrewsand remove the consolefrom the vehicle.

*If equippedwith SRS,dont allow any impact or shockto the SRSdiagnosticunit when removingthe floor console.
3. Loosenthe cableadjusternut,then remove the parkingbrakecableby pulling it from the passenger compartment. 4. Raisethe vehicleand supportit safely. 5. At the rearwheel,removethe brakecaliper and rotor. 6. Removethe parkingbrakeshoes. 7. Disconnect cableendfrom the parking the brakestrut lever. 8. Compressthe retainingstrips to removethe cablefrom the backingplate. 9. Unfasten otherframeretainersand reany movethe cables.

To install:
10. Installthe cableto the rearactuator.Securein placewith the parkingbrakecableclip and retainer spring. 11. Installthe parkingbrakeshoes. 12. Installthe brakerotor and caliperassembly. 13. Positionthe cableand looselyinstall the retainers. 14. Reattach parkingbrakecablesto the actuthe ator insidethe vehicle. 15. Tightenthe adjustingnut until the propertension is placedon the cable. 16. Adjustthe parkingbrakestrokeusing appropriatemethod. 17. Secureall cable retainers. 18. Apply and releasethe parkingbrakea number of times onceall adjustments havebeenmade. 19. Assemblethe interior components which were removed. 20. Adjustthe parkingbrakeshoesand parking brakecables. 21. Connectthe negativebatterycable. 22. Checkthe rearwheelsto confirmthat the rear brakesare not dragging. 23. Checkthatthe parkingbrakeholdsthe vehicle on an incline.

To install:
IO. Installthe cableto the rearactuator.Securein placewith the parkingbrakecableclip and retainer spring. Il. Installthe parkingbrakeshoes. 12. Installthe brakerotor and caliperassembly. 13. Positionthe cableand looselyinstall the retainers. 14. Reattach parkingbrakecablesto the actuthe ator insidethe vehicle. 15. Tightenthe adjustingnut until the propertension is placedon the cable. 16. Adjustthe parkingbrakestrokeusingappropriatemethod. 17. Secureall cableretainers. 18. Apply and releasethe parkingbrakea number of times onceall adjustments havebeenmade. 19. Assemblethe interiorcomponents which wereremoved. 20. Adjustthe parkingbrakeshoesand parking brakecables. 21. Connectthe negativebatterycable. 22. Checkthe rearwheelsto confirmthat the rear brakesare not dragging. 23. Checkthatthe parkingbrakeholdsthe vehicle on an incline.

) See Figure 109

Unlikeconventionalreardisc brakesystems,the parkingbrakeoperationis NOTincorporated the into brakecaliper.This system,usesa separate of set brakeshoes,locatedbehindthe brakerotor. 1. Disconnectthe negativebatterycable.

The SRScontrol unit is mountedbeneaththe centerconsole. Usecare whenworking with the center consoleassemblynot to impactor shockthe control unit.
2. Removethe centerfloor consoleassemblyas follows: a. Removethe shifter knob on models equippedwith a manualtransaxle.

ADJUSTMENT
Mirage ) See Figure 110 *If the vehicle is equippedwith rear drum brakes, makecertain that the brakeshoes are properly adjustedbefore attemptingto adjustthe parkingbrake.
Floor console

Diamante
Unlikeconventionalreardisc brakesystems,the parkingbrakeoperationis NOTincorporatedinto the brakecaliper.This system,usesa separate of set brakeshoes,locatedbehindthe brakerotor. 1. Disconnectthe negativebatterycable.

Workmust be startedafter 90 secondsfrom the time the ignition switch is turnedto the LOCK position and the negativebattery cable is disconnected.
8. 0 10. 11. 12. 13. 14 Stnd return aring Shwhdd-downcup shna hchd-dPwn SpnnQ Shm hold-dcwn pm shoe and lllllnp us*mbly cap PwkilvJbnko~

*If equippedwith an air bag, be sure to disarm it before starting repairs on the vehicle.
2. Removethe centerfloor consoleassemblyas follows: a. Removethe ashtrayor consoleswitch panelfrom the consoleassembly. b. Removethe two screwsfrom the centerof the console.
93159936

93159g24

Fig. 109 Explodedview of parking brake components (with disc brakerear system)1994-95 Galant

Fig. 110 Parking brake adjusting nutMirage

BRAKES 9-23
1. Makesurethe parkingbrakecable is freeand is not frozenor sticking. 2. Apply the parkingbrakewith 45 Ibs. (200 N) of force while countingthe numberof notches.Thedesired parkingbrakestrokeshouldbe 5-7 notches. 3. If adjustmentis required,accessthe adjusting nut from insidethe floor console. 4. Loosenthe locknuton the cablerod. 5. Rotatethe adjustingnut to adjustthe parking brakestroketo the 5-7 notchsetting.After making the adjustment, checkthereis no loosenessbetween the adjustingnut andthe parkingbrakelever,then tightenthe locknut. g. Installthe caliperand checkoperation. 3. Oncethe parkingbrakeshoeshavebeenproperly adjusted,adjustthe cablemechanism, perby forming the following steps: _ a. Turn the adjustingnut to give the proper numberof clicks whenthe lever is raisedfull travel. b. Raiseand supportthe rear of the car on jackstands. c. Release brakelever and makesurethat the the rear wheelsturn freely. If not, back off on the adjustingnut until they do.

*The parkingbrakeshoesmustbe adjusted before attemptingto adjustthe cable mechanism

2. To adjustthe parkingbrakeshoes,performthe following steps: a. Removethe floor console,releasethe lever and backoff the cableadjusterlocknutat the baseof the lever. b. Raisethe vehicle,supportsafelyand remove the wheel.Removethe hole plug in the brakerotor. c. Removethe brakecaliper and hang out of the way with wire, Do not disconnectthe fluid line. d. Use a suitableprybarto pry up on the selfadjusterwheel until the rotor will not turn. e. Returnthe adjuster5 notchesin the opposite direction,Make sure the rotor turns freely with a slight drag. f. Install the caliper and checkoperation. 3. Oncethe parkingbrakeshoeshavebeenproperly adjusted,adjustthe cablemechanism, perby forming the following steps: a. Pull the parking brakelever up with a force of 45 Ibs. (200 N). The total numberof clicks heardshould be 3-5. to b. Turn the adjustingnut give the proper numberof clicks whenthe lever is raised. c. Raiseand supportthe rear of the car on jackstands. d. Release brake leverand makesure that the the rear wheelsturn freely.

*Do not adjustthe parkingbraketoo tight. If the numberof notchesis less than specification, the cable has beenpulled too muchand the automaticadjusterwill fail or the brakes will drag.
6. Afteradjustingthe leverstroke,raisethe rearof the vehicleand safelysupport.With the parkingbrake lever in the released position,turn the rearwheelsto confirmthat the rearbrakesare not dragging. 7. Checkthat the parkingbrakeholdsthe vehicle on an incline.

1994470VEHICLES
1, Pull the parkingbrakeleverwith a force of approx. 45 Ibs.(200 N) and countthe numberof notches.Standard valueis: 5-7 notches.

The 45 lbs. (200N) force of the parkingbrake lever mustbe strictly observed.
2. If the parkingbrakelever is not the standard value,adjustin the following manner: a. Removethe inner compartmentmat of the floor console b. Loosenthe adjustingnut at the end of the cable rod, freeingthe parking brake. c. With the engine idling, forcefullydepress the brakepedalfive or six times and confirm that the pedalstrokestops changing.If the pedal stroke stops changing,the automatic-adjustment mechanismis functioningnormally,and the clearancebetweenthe shoe and the drum is correct. d. After adjustingthe parking brakelever stroke,safelyraise and supportthe rear of the vehicle and with the parkingbrake lever in the releasedposition, turn the rearwheelsto confirm that there is no brakedrag.

Galant
\

1990-93 VEHICLES # See Figure 111

1. Pull the parkingbrakeleverup with a force of about45 Ibs. (200 N). Thetotal numberof clicks heardshouldbe 5-7 clicks. If the numberof clicks was not within that range,the systemrequiresadjustment.

REMOVAL &INSTALLATION 1994-00 Galantand 1992-96 Diamante # See Figures112, 113, and 114
1. Raiseand safelysupportthe vehiclesecurely on jackstands. 2. Removethe caliperassembly. 3. Removethe rearbrakerotor.

*The parkingbrakeshoesmustbe adjusted before attemptingto adjustthe cable mechanism

2. To adjustthe parkingbrakeshoesperformthe following steps. a. Removethe floor console,releasethe lever and back off the cableadjusterlocknutat the baseof the lever. b. Raisethe vehicle,supportsafelyand remove the wheel. c. Removethe hole plug in the brakerotor. d. Removethe brakecaliperand hangout of the way with wire. Do not disconnectthe fluid line. e. Use a suitableprybarto pry up on the selfadjusterwheel until the rotor will not turn. f. Returnthe adjuster5 notchesin the opposite direction. Make sure the rotor turns freely with a slight drag.

Diamante
1. Pull the parkingbrakeleverup with a force of about45 Ibs.(200 N). Thetotal numberof clicks heardshouldbe 3-5. If the numberof clicks was not within that range,the systemrequiresadjustment.

93159901

93159902

Fig. 111 Parking brake system adjustment points-1993 Galant

Fig. 112 Explodedview of the parkingshoes and related components-1994-00 Galant with disc brakes

Fig. 113 Explodedview of the parkingbrake shoes and related components-1992-96 Diamante

9-24 BRAKES
the vehicleand the shoeadjustingbolt of the right handwheelis towardthe rearof the vehicle. 12. The load on the respectiveshoe-to-anchor springs is different,so the spring in the figure has hen painteb,a>shm in the a~~0mparrying figure. Shoe-to-anchor spring (rear) e Forward
69579946

1997-00 Diamante ) See Figure 115

1. Raiseand safelysupportthe vehiclesecurely on jackstands. 2. Removethe caliperassembly. 3. Removethe rearbrakerotor.

3. Removethe hole plug in the brakerotor. 4. Removethe brakecaliperand hangout of the way with wire. Do not disconnectthe fluid line. 5. Usea suitableprybarto pry up on the self-adjuskrV&I&I tie T&IT wi\\ not tirn. unti\ 6. Returnthe adjuster5 notchesin the opposite direction.Makesurethe rotor turns freelywith a slight drag. 7. Installthe caliperand checkoperation.

Fig. 114 Shoe-to-anchorspring installation only *When servicing drumbrakes, dissemble andassembleone side at a time, leaving the remainingside intact for reference.
4. Removethe front and rearshoe-to-anchor springs. 5. Removethe adjustingwheelspring and the adjuster. 6. Removethe strut andthe strut returnspring. 7. Removethe shoe hold-downcup,spring and pin. 8. Removethe shoeand lining assembly. 9. Unfasten clips and the retainingbolts, the then removethe parkingbrakecable(s).

*When servicing drumbrakes,only dissemble and assembleone side at a time, leaving the remainingside intact for reference.
4. Removethe shoehold-downspring retaining screw. 5. Removethe shoehold-downspring. 6. Removethe shoeassemblyfrom the backing plate. 7. The installationis the reverseof removal.

ADJUSTMENT
1. Removethe floor console,releasethe lever and backoff the cableadjusterlocknutat the baseof the lever. 2. Raisethe vehicle,supportsafelyand remove the wheel.
9. Shoe

To install:
10. Installationis the reverseof the removalprocedure. 11. Installthe adjusterso the shoeadjustingbolt of the left handwheelis attached towardthe front of

93159go3

Fig.115 Explodedview of the parking brake shoes and related components-l 997-00 Diamante

The4-WheelAnti-lock BrakeSystem(ABS) is an electronically operated, wheelbrakecontrol sysall tem. Major componentsincludethe vacuumpower brakebooster,mastercylinder,the wheelspeedsensors,the HydraulicControlUnit (HCU),Anti-lock control unit, a relay,and on the AWD Galant, G sena sor. The systemis designedto retardwheellockup duringperiodsof high wheelslip whenbraking.Retardingwheellockupis accomplished modulating by fluid pressureto the wheelbrakeunits.Whenthe control unit detectsa variation in voltageacrossthe wheelspeedsensors,the ABS is activated.Thecontrol unit opensand closesvarious valves locatedinsidethe HCU.Thesevalves,calleddumpand isolation valves,modulatethe hydraulicpressure the to wheelsby applyingand ventingthe pressure the to brakefluid circuits.

PRECAUTIONS
l Certaincomponents within the Anti-Lock Brake System(ABS)are not intended beservicedor reto pairedindividually.Onlythosecomponents re- ! with moval and installationprocedures should beserviced. 0 Do not use rubberhosesor otherpartsnot specificallyspecifiedfor an ABSsystem.Whenusing repairkits, replaceall parts includedin the kit. Partial or incorrectrepairmay leadto functionalproblems and requirethe replacement components. of

l Lubricaterubberpartswith clean,fresh brake fluid to easeassembly.Do not use lubricatedshop air to cleanparts;damage rubbercomponentsmayreto sult. l Useonly specifiedbrakefluid from an unopenedcontainer. l If any hydrauliccomponentor line is removed or replaced,it may be necessary bleedthe entire to system. l A cleanrepairareais essential.Alwaysclean the reservoirand capthoroughlybeforeremovingthe cap.Theslightestamountof dirt in the fluid mayplug an orifice and impairthe systemfunction.Performrepairsaftercomponentshavebeenthoroughly cleaned;useonly denatured alcoholto cleancomponents.Do not allow ABS components come into to contactwith any substance containingmineraloil; this includesusedshop rags. l TheAnti-Lock control unit is a microprocessor similar to othercomputerunits in the vehicle.Ensure thatthe ignition switch is OFFbeforeremovingor installing controllerharnesses. Avoid staticelectricity dischargeat or nearthe controller. l If anyarc welding is to be doneon the vehicle, the control unit should be unplugged beforewelding operationsbegin.

tools, specialtest harnesses otherspecialand and expensivetools. Alternativemethodsand common sensecan besubstituted, however,We at Chiltonfeel that it is beyondthe scopeof the averagedo-it-yourselfer.If you experience amberANTI LOCKlight the on in the instrumentclusterof your vehicle,checkthe fluid level in the mastercylinderfirst. Low fluid level will usuallyilluminatethe red BRAKE lamp in the instrumentclusteras well as, but not always,the amber ANTI LOCKlamp in the instrument cluster.The low fluid levelcould indicatea leak,but sometimesjust indicateslow,worn brakelinings that havecausedthe caliperpistonsandwheelcylindersto extendfurther, and thus using morefluid to exertforce on them. Inspectthe brakesystemfor hydraulicfluid leaksand also inspectthe brakelinings for excessivewear.

) See Figures 116 thru 123

The diagnosisof the ABS systemis rathercomplex and requiresquite a few specialtools includingscan

89579956

Fig. 116 You can connecta scan tool to the data link connectorto retrieve ABStrouble codes

BRAKES 9-25
Diagnostic trouble code No. 11 12 13 14 15 16 inspection item Diagnostic content Detection conditions

Right front wheel speed sensor Left front wheel speed sensor Right rear wheel speed sensor Left rear wheel speed sensor Wheel speed sensor system Power supply system Right front wheel speed sensor

Open circuit

Abnormal

output signal

B A, B

89579g53

r21 I
I

Abnormal battery positive voltage 1 Excessive gap or short circuit

Fig. 119 ABSdiagnostictrouble code list1990-93 Galant

LOCKwarninglampwill flash eithertwice (FWD)or 4 times (AWD)vehicles,in about1 secondwith the ig, nition switch ON , thenthe lampwill turn OFF. The DiagnosticTroubleCodes(DTC)arean alphanumeric codeand a scantool, suchas DRB-III, MUT-II or equivalentdiagnosticscantool, is required to retrievethe codes.Referto the scantool manufacturers instructionsfor operatingthe tool and retrieving the codes. The DataLink Connector(DLC) for the ABS is locatedunderthe dashon the driversside. It is the sameconnectorusedfor the electronicenginecontrol system.

22 23 24 36

Left front wheel speed sensor Right rear wheel speed sensor Left rear wheel speed sensor Stop light switch system Right front solenoid valve system

Open circuit or ON malfunction

I

A, B A, B

I 5

I Valve

relay system

1 Valve relay OFF failure Motor relay OFF failure and motor drive failure Malfunction in ABSECU (program maze, etc.)

A, 8

53 63

1 Motor relay or motor system ABS-ECU

Detection

conditions check immediately after starting

!
B
1 I I I

A, B

REMOVALANDINSTALLATION
The HydraulicControlUnit (HCU) is locatedin the enginecompartment. containsthe solenoidvalves It andthe pump/motorassemblywhich providespressurizedfluid for the anti-lock systemwhennecessary. Hydraulicunits are not interchangeable anyvehion cles Neitherunit is serviceable;if any fault occurs within the hydraulicunit, the entireunit must be replaced.

A: During system B: When driving

89579954

Fig. 117 ABSdiagnostictrouble code list-1992-96 Diamante

Diagnostrc trouble code no.
11

Inspection

item I Open circuit I

Detectron condalons

12 13 14
15

16 21

1 Front right wheel speed SensOr 1 Front left wheel speed sensor 1 Rear right wheel speed sensor Rear left wheel speed sensor Wheel speed sensor output signal abnormal Power supply system Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Stop light switch system 1 Front right solenoid valve (inlet) Front left solenoid valve (inlet) Rear right solenord valve (inlet) Rear left solenoid valve (inlet) Front right solenoid valve (outlet) Front left solenoid valve (outlet) Rear nght solenoid valve (outret) Rear left solenoid valve (outlet) Valve relay Motor relay ABSECU

Diamante b See Figure 124

1. Disconnect negativebatterycable. the 2. Removethe splashshield from beneath the vehicle. 3. Usea syringeor similar deviceto removeas muchfluid as possiblefrom the reservoir.Somefluid will be spilledfrom lines during removalof the hydraulic unit; protectadjacentpaintedsurfaces.

lBsC A B A, B, C

22
23 24 38 41 42 43 44 45 46 47 48 51 53 63

Short circuit

8, c

B. C I 0.c

- B,C

A 6, c B A B, c

Detection conditions A: During system check immediately 6: While ABS control is not operating C: While ABS control is operating

after starting while driving 93159go4

Brakefluid containspolyglycol ethersand poly9lycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If you do 9et brakefluid in your eyes, flush your eyes with clean, runningwater for 15 minutes.If eye irritation persists, or if you havetaken brakefluid internally, IMMEDIATELY medicalassistance. seek
4. Lift the relaybox with the harnessattached and position it aside. 5. Removethe air intakeduct. 6. Disconnect brakelines from the hydraulic the unit. Correctreassembly critical. Labelor identify is the lines beforeremoval.Plugeachline immediately

Fig. 118 ABSdiagnostic trouble code list-1997-00 Diamante

TheABS control unit performssystemtestsand self-testsduring startupand normaloperation.The valves,wheelsensorsand fluid levelcircuits are monitoredfor properoperation.If a fault is found,the ABSwill be deactivated the amberANTI LOCK and light will be lit until the ignition is turnedOFF.When the light is lit, the DiagnosticTroubleCode(DTC) may be obtained.Undernormaloperation,the ANTI-

Diagnostic trouble code no. 11 12 13 14 16 21 22 23 24 25 26 27 26 33 35 36 37

InspeclM

item

Detection conditions Open circuit 6 c

Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Power supply system Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensof Rear left wheel speed sensor Front right wheel speed sensor Front left wheel speed sensor / Rear right wheel speed sensor 1 Rear left wheel speed sew Stop light switch system Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor

Short circuit

4 0. C 0, c

Excessive gap

B, c

Pulse orocessina pheei speed in&t corresponding to a vehicle speed of 300

46 51 52 53 54

Rear left solenoid valve (outside) Valve relay Vti relay Motor relay Motor relay

ON impossible OFF impossrble ON impossible OFF impossible

A B. C A B B, c

Detection conditions
A: During system check immediately after starting 8: While ABS control is not operating while driving C: While ABS control is operating 93159go5

Fig. 120 ABSdiagnostic trouble code list-1994-98 Galant

DIAGNOSTIC TROUBLE CODE NO. 11 12 13 14 16 INSPECTION ITEH DIAGNOSTIC CONTENT

Fig. 122 ABSdiagnostic trouble code list-1993-96 Mirage

Front right wheel speed Sensor Front left wheel speed sensor Rear right wheel speed SBnsor Fear left wheel speed ssnsor Power supply system

Open circuit or short circuit

ABS-ECU power supply voltage below or above the standard value. Not displayed if the voltage recovers.

21 22 23

Front right wheel speed sensor Front left wheel speed sensor Rear right whesl sped sensor

~
Hydraulic unit aolenoid valve relay open or short circuit

93159906

Fig. 121 ABSdiagnostic trouble code list-1999-00 Galant

BRAKES 9-27

93159g17

Fig. 124 HCUmounting-Diamante

afterremoval.It will be necessary hold the relay to box asideto allow wrenchaccess. 7. Detachthe wiring harnessconnectionsat the hydraulicunit. 8. Disconnect hydraulicunit groundstrap the from the chassis. 9. Removethe 3 bolts holdingthe hydraulicunit bracket.Removethe unit andthe bracket.

*The hydraulicunit is heavy;use care when removingit. The unit mustremain in the upright position at all times and be protected from impactandshock.
IO. Setthe unit upright,supportedby blockson the workbench. hydraulicunit must not betilted The or turnedupsidedown.No componentof the hydraulic unit shouldbe loosenedor disassembled. 11. Loosenthe nut holdingthe bracketto the hydraulic unit and removethe bracket. 12. Disconnect externalgroundwire from the the bracket.

1. 2. 3. 4. 5. 6. 7. 8.

Bracket Air conditioning relay box Oil reservoir Motor relay Valve relay Brake pipe Hydraulic unit Hydraulic unit bracket

Fig. 125 HCUmounting-Mirage or if you havetaken brakefluid internally, IMMEDIATELY medicalassistance. seek
2. Removethe splashshieldfrom the leftfront wheelhouseor fenderarea. 3. Removethe coolantreservetank. 4. Removethe coolantreservoirbracket. 5. Removethe dust shield from belowthe hydraulic unit. 6. Disconnect brake the hosesand lines from the hydraulicunit. Correctreassembly critical. Lais bel or identifythe lines beforeremoval.Plugeach line and eachport immediatelyafterremoval. 7. Removethe cover from the relaybox. Disconnectthe electricalharnessto the hydraulicunit. 8. Removethe bolts holdingthe 3 mounting brackets the vehicle;removethe unit downward to and out of the vehicle.

Fig. 126 HCUmounting-Galant

17. Fill the reservoirto the MAXline with brake fluid. 18. Bleedthe brakesystem. 19. Installthe dust shield andthe coolantreserve tank with its bracket. 20. Installthe fendersplashshield. 21. CheckABSsystemfunction by turningthe ignition ON and observingthe dashboard warning lamp.Testdrive the vehicleand confirm systemoperation.

To install:
13. Installthe bracketif removed. 14. Connectthe groundwire to the bracket. 15. Installthe hydraulicunit into the vehicle, keepingit uprightat all times. 16. Installthe retainingnutsand tighten. 17. Connectthe hydraulicunit wiring harness. 18. Connecteachbrakeline looselyto the correct port and doublecheckthe placement. Tighteneach line to 11 ft. Ibs.(15 Nm). 19. Fill the reservoirto the MAX line with brake fluid. 20. Bleedthe mastercylinder,thenbleedthe brakelines. 21. Securethe relaybox in positionand install the air duct. 22. Installthe splashshield.

REMOVALANDINSTALLATION
) See Figures127 and 128
1. Ensure the ignition switch is OFFthroughthat out the procedure. 2. For Galantand Diamantemodels,removethe left side luggagecompartment panel. trim 3. For Mirage models,removethe floor console assembly. 4. Release lock on the bottomof the connecthe tor. Detachthe multi-pin connectorfrom the control unit. 5. Removethe retainingnutsand removethe control unit from its bracket.The bracketmaybe removedif desired.

*The hydraulicunit is heavy;use care when removingit. The unit mustremain in the upright positionat all times and be protected from impactand shock.
9. Setthe unit upright,supportedby blockson the workbench. hydraulicunit must not betilted The or turnedupsidedown. No componentof the hydraulic unit should be loosenedor disassembled. 10. The bracketsand relaysmaybe removedif desired.

Galantand Mirage ti See Figures125 and 126

1. Usea syringeor similar deviceto removeas muchfluid as possiblefrom the reservoir.Somefluid will bespilled from lines during removalof the hydraulic unit; protectadjacentpaintedsurfaces.

To install:
11. Installthe bracketsand relaysif they wereremoved.Tightenthe bracketboltsto 16 ft. Ibs.(22 Nm). 12. Installthe hydraulicunit into the vehicle, keepingit uprightat all times. 13. Installthe retainingbolts holdingthe brackets to the vehicle.Tightenthe bolts to 16 ft. Ibs. (22 Nm). 14. Connectthe hydraulicunit wiring harness. 15. Installthe cover on the relaybox. 16. Connecteachbrakeline looselyto the correct port and doublecheckthe placement. Tighteneach line to IO ft. Ibs. (13 Nm).

To install:
6. Placethe bracketin position if it was removed. Installthe controllerandtightenthe retainingnuts. 7. Connectthe groundwire to the bracket,if removed.Insurea proper,tight connection.Theground must be connected beforethe multi-pin harnessis connected. 8. Attachthe multi-pin connectorand securethe lock. 9. Installthe luggagecompartment or the trim floor console.

Brakefluid containspolyglycol ethersand polyglycols. Avoid contactwith the eyes and wash your handsthoroughlyafter handling brakefluid. If you do get brakefluid in your eyes, flush your eyeswith clean, runningwater for 15 minutes.If eye irritation persists,

9-28 BRAKES
Galant FRONT # See Figures 131 and 132
1. Disconnect negativebatterycable.Wait at the least90 secondsbeforeperforminganywork. 2. Raiseand safelysupportthe vehicle.Remove the necessary andwheelassembly. tire 3. Removethe fendersplashshield. 4. Detachthe ABS speedsensorconnector. 5. Removethe sensorharnessclampbolts and clamps. 6. Removethe ABSspeedsensormountingbolt and the sensor.

1. ABS-ECU 2. ABSECU 3. Bracket

ccr~nector

1. Electronic 2. Bracket

control

una

93159912

Fig. 127 Anti-lock control unit mountingMirage

Fig. 128 Anti-lock control unit mountingGalant and Diamante

8. Installthe sensorwire harnessand attachthe connector, 9. Usinga non-magnetic feelergauge,adjust the sensorair gap so the clearancebetween rotor the andthe sensoris 0.012-0.035 inches(0.3-0.9mm). IO. Tightenthe sensorbracketand recheckthe clearance. 11. Connectthe negativebatterycable.

To install:
7. Installthe ABS speedsensorwith its mounting bolt.

REMOVAL&INSTALLATION Mirage FRONT I) See Figure 129

1, Disconnect negativebatterycable. the

*The clearancebetweenthe wheel speed sensorandthe rotors toothedsurface is not adjustable,but measurethe distancebetween the sensorinstallation surfaceandthe rotors toothedsurface. Standardvalue is: 1.11-1.I2 in. (28.2-28.4mm).If not within specifications,replacethe speedsensoror the toothedrotor.

Speed sensor

Wait at least 90 secondsafter the negative batterycable is disconnected preventposto sible deploymentof the air bag.
2. 3. 4. 5. 6. Raiseand safelysupportthe vehicle. Removethe splashshield. Detachthe speedsensorconnector. Removethe clips holdingthe sensorharness. Removethe speedsensorfrom the bracket.

Feeler gauge
93159g35

To install:
7. Installthe speedsensorto the bracketand securewith mountingbolt. 8. Installthe clips holdingthe sensorharness. 9. Attachthe speedsensorconnector. IO. Connectthe negativebatterycable.

Fig. 129 Front and rear wheel speed sensors-Mirage

Fig. 130Adjustingthe rear speedsensorair gap-Mirage

REAR 8 See Figure 129 and 130

1. Disconnect negativebatterycable. the
6

Wait at least 90 secondsafter the negative batterycable is disconnected preventposto sible deploymentof the air bag.
2. Raiseand safelysupportthe vehicle. 3. Detachthe speedsensorconnector. 4. Removethe clips holdingthe sensorharness. 5. Removethe mountingbolt and the speed sensor.

To install:
6. Installthe speedsensorand looselytighten the mountingbolt, 7. Installthe clips holdingthe sensorharness.

1 3. Front speed sensor connwxwn 4 Fmnt sweed sensor 5 Front speed sensor bracket 6 Rear toothed rotor 8 Cabletand 8 Rear speed sensor connection 10 Rear speed sensx 12 omg

93159934

Fig. 131 Wheel speed sensors-1990-93 RWDGalant

Fig. 132 Wheel speed sensors-1994-00 Galant

BRAKES 9-29
8. Reinstallthe sensorharnesswith its clamps and bolts. 9. Reconnect speedsensorconnector. the IO. Installthe fendersplashshield. 11. Reinstallthe tire andwheel,safelylowerthe vehicle,and reconnect negativebatterycable. the REAR

To install:
7. Installthe speedsensorandtorqueto 9 ft. Ibs. (12 Nm). 8. Installthe clips holdingthe sensorharness. 9. Connectthe speedsensorconnector. IO. Connectthe negativebatterycable. REAR

2. For the rear sensor,removethe trunkfloor mat. 3. Disconnect G-sensorwiring harness. the 4. Removethe coverfrom the rearsensor.Removethe sensorfrom the bracket.Removethe bracketif desired.

To install:
5. Reinstallthe bracketif it was removed. 6. Installthe G-sensorand connectthe wiring harness. Tightenthe retainingbolts to 8 ft. Ibs. (11 Nm). 7. Installthe cover on the rearG-sensor. 8, Installthe consoleand/orthe trunkfloor mat or carpet.

) See Figure 131 and 132

1. Disconnect negativebatterycable.Waitat the least90 secondsbeforeperforminganywork. 2. Raiseand safelysupportthe vehicle.Remove the necessary andwheelassembly. tire 3. Detachthe ABSspeedsensorconnector. 4. Removethe sensorharnessclampbolts and clamps. 5. Removethe ABSspeedsensormountingbolt and the sensor.

I) See Figure 133

1. Disconnect negativebatterycable. the

Workmustbe startedafter 90 secondsfrom the time the ignition switch is turnedto the LOCK position andthe negativebatterycable is disconnected.
2. Raiseand safelysupportthe vehicle. 3. Detachthe speedsensorconnector. 4. Removethe clips holdingthe sensorharness. 5. On AWDmodels,removethe cableband. 6. Removethe mountingbolt andthe speed sensorwith the O-ring.

REMOVAL INSTALLATION &

Front
1. Raiseand safelysupportthe vehicle. 2. Removethe wheeland tire. 3. Removethe wheelspeedsensorand disconnectsufficientharnessclips to allow the sensorand wiring to be movedout of the work area.

To install:
6. Installthe ABS speedsensorwith its mounting bolt.

*The clearancebetweenthe wheel speed sensorandthe rotors toothedsurfaceis not adjustable,but measurethe distancebetween the sensorinstallation surfaceandthe rotors toothedsurface. Standardvalue is: 1.11-l .I2 in. (28.2-28.4mm).If not within specifications, replacethe speedsensoror the toothedrotor.
7. Reinstallthe sensorharnesswith its clamps and bolts. 8. Reconnect speedsensorconnector. the 9. Reinstallthe tire and wheel,safelylowerthe vehicle,and reconnect negativebatterycable. the

To install:
7. Installthe speedsensorwith the O-ring and torqueto 9 ft. Ibs.(12 Nm). 8. Installthe clips holdingthe sensorharness. 9. Installthe cableband. 10. Installthe sensorwire harnessand connect the connector. 11. Connectthe negativebatterycable.

*The speedsensorhas a pole piece projecting from it. This exposedtip mustbe protectedfrom impactor scratches.Do not allow the pole pieceto contactthe toothed wheel duringremoval or installation.
4. Removethe front hub and knuckleassembly. 5. Removethe hubfrom the knuckle. 6. Supportthe hub in a vise with protected jaws. 7. Removethe retainingboltsfrom the toothed wheeland removethe toothedwheel.

Diamante
FRONT

* See Figure 133

1. Disconnect negativebatterycable. the

The G-sensorsare usedonly on the AWDvehicles.The rear is mountedin the trunk underthe floor matwhile the front sensoris underthe consoleassembly.Thesensortransmitsacceleration deceland erationinformationto the anti-lock control unit. This datais usedin conjunctionwith individualwheel speedand enginedata,allowingthe controllerto determinethe approximateroadfriction. This friction factor is then usedto computethe propercontrol of the solenoidvalves.

To install:
8. Fit the newtoothedwheelonto the hub and tightenthe retainingbolts to 7 ft. Ibs. (10 Nm). 9. Assemblethe hubto the knuckle IO. Installthe hub and knuckleassemblyto the vehicle. 11. Installthe wheelspeedsensor. 12. Installthe wheeland tire. 13. Lowerthe vehicleto the ground.

Workmustbe startedafter 90 secondsfrom the time the ignition switch is turnedto the LOCK position andthe negativebattery cable is disconnected.
2. 3. 4. 5. 6. Raiseand safelysupportthe vehicle. Removethe splashshield. Detachthe speedsensorconnector. Removethe clips holdingthe sensorharness. Removethe speedsensor.

REMOVAL&INSTALLATION
# See Figure 134
1. Forthe front sensor,removethe consoleassembly.

Rear
EXCEPT AWD GALANT 1. Raiseand safelysupportthe vehicle. 2. Removethe wheelandtire. 3. Removethe wheelspeedsensorand disconnectsufficientharnessclips to allow the sensorand wiring to be movedout of the work area.

*The speedsensorhas a pole piece projecting from it. This exposedtip mustbe protectedfrom impactor scratches.Do not allow the pole piece to contactthe toothed wheel duringremoval or installation.
4. Removethe hubassembly. 5. Supportthe hub in a vise with protected jaws. 6. Removethe retainingboltsfrom the toothed wheeland removethe toothedwheel.
Th, - ape.24 m-5 un Ntvmsa*.

-lkol*) 1 wimp--vx 2 Gasnan Im0 3. Gmwor LmcM Bmar 1 Front toothed rotor 2 Ckp 3 Front speed sensor 4 Front speed aenmr t bracket ;5 toothed rotor burl : wwzh&T&m~mm6 G.smsol Ired 7 c-.elwnbRcta

To install:
93159909

I Rear speed SB"SO, 93159016

Fig. 133 Wheel speed sensors-Diamante

Fig. 134 Front and rear G-sensor mounting-l 990-93 AWDGalant

7. Fit the newtoothedwheelonto the hub and tightenthe retainingbolts to 7 ft. Ibs. (10 Nm). 8. Installthe hub assemblyto the vehicle.The centerhub nut is not reusable. newnut must be The

9-30 BRAKES
tightenedto 144-188 ft. Ibs.(200-260 Nm).Afterthe nut is tightened, align the nut with the spindle indentationand crimp the nut in place. 9. Installthe wheelspeedsensor. 10. Installthe wheeland tire. 11. Lowerthe vehicleto the ground. 5. Removethe brakecaliperand brakedisc. 6. Removethe 3 retainingnutsand bolts holding the outerend of the driveshaftto the companion flange. 7. Swingthe axle shaftawayand supportit with stiff wire. Do not overextend joint in the axle;do the not allow it to hangunsupported. , 8. Removethe retainingnut and washeron the backof the driveshaft.Usespecialtool MB 9967 or equivalentto counterhold hub. the 9. Removethe companionflangefrom the knuckle. IO. Usingan axle pullerwhich bolts to the wheel lugs, removethe axle shaftassembly. 11. Fit the shaftassemblyin a presswith the toothedwheelcompletelysupportedby a bearing platesuchas specialtool MB 9e60 or its equivalent. 12. Pressthe toothedwheeloff the axle shaft. 14. Installthe axle shaftto the knuckleand fit the companionflangein place. 15. Installthe lock washerand a newself-locking nut on the axle shaft.Tightenthe nut to 116-159 ft. Ibs. (160-220 Nm). 16. Swingthe axle assemblyinto placeand install the 3 nutsand bolts.Tighteneachto 45 ft. Ibs. (61Nm). 17. Installthe brakedisc and caliper. 18. Installthe wheelspeedsensor.Alwaysusea newO-ring. 19. Connectthe parkingbrakecableto the caliper. 20. Installthe wheelandtire; lowerthe vehicleto the ground.

AWD GALANT
1. Raiseand safelysupportthe vehicle. 2. Removethe wheelandtire. 3. Disconnect parkingbrakecablefrom the the caliper. 4. Removethe speedsensorand its O-ring. Disconnectsufficientclampsand wire ties to allow the sensorto be movedwell out of the work area.

*The speedsensorhas a pole piece projecting from it. This exposedtip mustbe protectedfrom impactor scratches.Do not allow the pole piece to contactthe toothed wheel duringremoval or installatlon.

To install:
13. Pressthe newtoothedwheelonto the shaft with the groovefacingthe axle shaftflange.

Thereis no specialprocedure bleedthe ABS to system.Proceedwith the normalbrakebleedingprocedurelocatedearlier in this section.

BRAKE SPECIFICATIONS
All measurements
Brake Disc Original Minimum Thickness Thickness 0.940 0.882 0.940 aO.882 0.390 0.331 0.510 0.449 0.940 0.882 0.390 0.331 0.940 0.882 _ 0.940 0.882 0.390 0.331 0.510 0.449 0.710 0.646 0.940 '0.882 0.390 0.331 0.940 0.882 0.710 0.646 0.940 0.882 NA 0.720 0.940 0.882 _ 0.940 0.882 0.390 0.331 0.510 .0.449 0.710 0.646 0.940 0.882 0.390 0.331 0.940 0.882 0.710 0.646 0.940 0.882 NA 0.720 0.940 0.882 0.940 0.882 0.390 0.331 0.510 0.449 _ _ 0.710 _ 0.710 0.390 0.940 0.710 0.940 NA 0.940 -I 0.940 0.390 0,510 _ 0.710 0.710 0.390 0.646 0.646 0.331 0.882 0.646 0.882 0.720 0.882 0.882 0.331 0.449 _ 0.646 0.646 0.331 Maximum Runout 0.003 0.003 0.003 0.006 0.003 0.003 0.003 0.003 0.003 0.006 0.006 0.006 0.006 0.003 0.003 0.003 0.003 0.003 0,003 0.003 0.006 0.006 0.006 0.006 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.006 0.006 0.006 0.006 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.006 0.006 0.006 0.006

in inches unless noted

Brake Original Inside Diameter 8.000 7.100 8.000 7.100 7.100 8.000 7.100 7.100 8.000 7.100 8.000 8.976 7.100 8.000 Drum Diameter Max. Maximum Wear Machine Limit Diameter 8.100 7.200 8.100 7.200 7.200 8.100 7.200 7.200 -8.100 7.200 8.100 9.078 7.200 8.100 Minimum Lining Thickness Front Rear 0.080 0.080 0.080 0.080 0.080 0.040 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.040 0.080 0.040 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.040 0.080 0.080 0.080 0.040 0.080 0.040 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.040 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.040 0.040 0.080 0.080 0.080 0.040 0.080 0.040 0.040 0.080 Brake CaliPer Bracket Miunting Bolts Bolts (ft. Ibs.) (ft. Ibs.) 58-72 16-23 58-72 16-23 36-43 16-23 58-72 16-23 58-72 46-62 58-72 16-23 58-72 46-62 58-72 46-62 36-43 16-23 58-72 0 58-72 27-36 58-72 46-62 36-43 16-23 65 54 36-43 20 65 54 36-43 20 58-72 46-62 58-72 46-62 36-43 16-23 58-72 0 58-72 27-36 58-72 46-62 36-43 16-23 65 54 36-43 20 65 54 36-43 20 58-72 46-62 58-72 36-43 58-72 58-72 58-72 36-43 65 36-43 65 36-43 65 65 36-43 58-72 58-72 58-72 36-43 46-62 16-23 0 0 CD 16-23 54 20 54 20 54 54 54 0 0 0 16-23

Year 1990

1991

iiz-

1993

~ F R F Galant R w/rear disc F Mirage R F Mirage R w/rear disc F Galant R F Galant R w/rear disc Mirage F R Solid rotor F Mirage R Vented rotor F Mirage R w/rear disc F Diamante R F Diamante R Wagon F Galant R F Galant R w/rear disc Mirage F R w/solid rotor F Mirage R w/vented rotor F Mirage R w/rear disc Diamante F R F Diamante Wagon R Galant F R Galant w/rear disc Mirage w/solid rotor Mirage w/vented rotor Mirage w/rear disc Diamante Diamante Wagon Galant Galant w/rear disc Mirage w/solid rotor Mirage w/vented rotor Mirage w/rear disc F R F R F R F R F R F R F R F R F R F R F R

Model Galant

im-

BRAKE SPECIFICATIONS
All measurements in inches unless noted
Brake Drum Diameter Minimum Brake Caliper Brake Disc Original Max. Maximum Lining Bracket Mounting Original Minimum Maximum Inside Wear Machine Thickness Bolts Bolts Model Thickness Thickness Runout Diameter Limit Diameter Front Rear Ht. Ibs.1 (ft. Ibs.) ' I 1 -Diamante 1 F 1 0.940 1 0.882 1 0.003 1 0.080 65 54 R 0.710 0.646 0.003 0.080 20 36-43 0.882 0.003 Diamante F 0.940 0.080 65 54 R NA 0.720 0.003 Wagon --iizG20 36-43 F 0.940 0.882 0.003 Galant 0.080 54 65 8.976 9.078 0.040 R F 0.940 0.882 0.003 0.080 Galant 54 65 R 0.390 0.331 0.003 wheardisc 36-43 54 0.449 0.006 Mirage F 0.510 0.080 58-72 0w/solid rotor 7.200 Mirage 0 w/vented rotor 8.100 t.710 1 0.646 1 0.006 1 Mirage 1 0.080 1 1 56-72 1 @ w/rear disc 1 R 1 0.390 1 0.331 1 0.006 I Diamante 65 0.080 54 F 0.940 0.882 0.003 0.080 36-43 20 R 0.710 0.646 0.003 Galant

Year 1995

1996

t--=-E5

-t-xii-

1997

isi-

Galant wheardisc Mirage w/solid rotor Mirage 1 wivented rotor Mirage w/rear*disc Diamante F R F Galant R F Mirage PI InI Diamante F t-t-R _ Gdi snt 1 F I
R

8.100 0.080 0.080 0.l380 8.976 9.078 0.l380 * n-a A #-A 1 LI.uuu 1 1 8.1UU 1 0.080 0.080 9.078 8.976 9.078 '0.080 8.00 8.10 8.10 1 0.080 0.080 8.976 9.078 9,078 0.080 8.10 8.00 8.10 0.080 0.080 8.976 9.078 9.078 0.080 1 I 1 8.00 1 8.10 1 8.10 I . 1

0.940 0.390 0.940 0.710 0 ,940 0 ,410 0.940

-

0.882 0.331 0.882 0,646 1 PPP0.880 0.330 0.880

_

0.003 0.003 0.003 0.006 0.002 0.0023 0.0031

-

Mirage 1999 Diamante Galant Mir; 2ooo Diamante Galant Mirlwe _

NA - Not Available F - Front R - Rear

F R F R F

R F R F R F i R 1

0.710 0.940 0I.410 01.940 0.710 0.940 0.410 0.940 0.710 1

0.650 0.880 0.330 0.880 0.650 _ 0.880 0.330 0.880 0.650 -

0.0024 0.002 0.0023 0.0031 0.0024 0.002 0.0023 0.0031 0.0024 1 -

0.040 0.080 0.080 0.040 0.040 0.039 0.040 0.039 0.039 0.040 0.039 0.039 0.040 0.039 I 1

58-72 36-43 65 36-43 65 67-81 54 24 54 L 36 54 24 54 36 ii 54 24 54 36 1

0 16-23 54 20 54 0 65 36-43 65 67-81 65 36-43 65

67-81 65 36-43 65 ,r 1 -

OUpper:39fLIbs. ,
Lower: 65 ft. Ibs.