Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide




Disc brakes are inherently self-adjusting, and set themselves automatically after linings are replaced when the brake pedal is applied.


Drum brakes do not require adjustment unless self adjusters give problems or linings are replaced. Adjustment for those models with rear drum brakes is given below.

With the vehicle safely supported and the rear wheels removed, turn the star wheel on the adjuster to adjust the outer diameter of the brake shoes. Measure accurately across the diameter of the outer brake surfaces. Correct distance is 9.96-9.98 in. (25.30-25.35cm) for both Montero and Pick-up. Notice that it is necessary to measure accurately to the tenth of a millimeter; use the correct tool.

Make certain the parking brake lever is fully released and the cable is not applying tension. Install the brake drum properly. Apply the parking brake via the lever and the service brakes via the pedal alternately until the shoes are adjusted. The "feel" of the pedal and the lever should remain constant.


See Figures 1, 2, 3, 4 and 5

  1. Measure the distance (height) from the top surface of the floor, not including the carpet, to the top surface of the brake pedal. Correct distance is:

    1983-91 Montero: 7.51-7.71 in. (19.1-19.6cm)
    1992-95 Montero: 7.3-7.51 in. (18.6-19.1cm)
    Pick-up: 6.54-6.73 in. (16.6-17.1cm)

  3. If the pedal height is not correct, move the brake light switch out of contact with the pedal arm.
  5. Loosen the lock nut on the pedal rod. Use pliers to turn the pedal rod, either lengthening it or shortening it, until the correct pedal height is obtained.
  7. Tighten the locknut. Reposition the brake light switch so that the distance between the outer case of the switch and the pedal is 0.019-0.039 in. (0.5-1.0mm). Note that the switch tab or prong must press against the pedal to keep the brake lights off.

Click image to see an enlarged view

Fig. Fig. 1: The brake pedal operating components-measure the distance from the pedal to the floor (A)

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Fig. Fig. 2: Use a pair of pliers to adjust the brake pedal operating rod to adjust measurement (A) to the standard specifications

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Fig. Fig. 3: Adjust the brake light switch so that there is 0.019-0.039 in. (0.5-1.0mm) between the outer case and the brake pedal

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Fig. Fig. 4: Measure the distance (B) between the pedal resting position and the point when resistance is felt

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Fig. Fig. 5: Measure distance (C) after depressing the brake pedal with approximately 110 lbs. (500 N) of force while the engine is running

  1. Tighten the locknut on the brake light switch.
  3. Check the free-play in the pedal. With the engine off, depress the brake pedal fully several times. Then check the movement in the pedal before any resistance is encountered. Correct free-play is:

    Monteros and Pick-ups: 0.12-0.31 in. (3-8mm)

  5. If there is no free-play in the pedal, check the adjustment of the brake light switch. If there is excessive free-play, look for wear or play in the clevis pin and brake pedal arm.
  7. Start the engine, depress the brake pedal with approximately 110 lbs. (500 N) of force, and measure the clearance between the brake pedal and the firewall.

    Pick-ups: 3.15 in. (80mm) or more.
    1983-91 Montero: 3.74 in. (95mm) or more.
    1992-95 Montero: 3.94 in. (100mm) or more.

  9. If the clearance is less than the standard value, check for air in the brake line or brake fluid leakage, and check the brakes themselves (for excessive shoe clearance caused by a malfunction of the automatic adjuster mechanism), and repair where necessary.