Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

Cables

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ADJUSTMENT



1983-91 Montero

WARNING
On vehicles with rear drum brakes, the shoe-to-drum clearance must be adjusted before adjusting the cable. If the brake clearance is out of adjustment, the cable adjustment will not cure the problem.

  1. Apply the brake with normal pressure (about 40 lbs. or 182 N) and count the number of clicks required to bring the lever tight enough to hold the vehicle. Don't try to pull the lever into the back seat, 4-5 clicks are sufficient. If the number of clicks is incorrect, proceed with the remaining steps.
  2.  
  3. Release the brake lever and tighten the cable adjuster (located under the vehicle, at the center of the cable equalizer) until all cable slack is just removed.
  4.  
  5. Start the engine, allowing it to idle and apply the footbrake and release it. Then apply the handbrake and release it, apply the footbrake and release it, etc. in a continuous cycle until the automatic adjusters at the rear stop clicking.
  6.  
  7. Recheck the number of clicks required to apply the brake. Adjust the cable adjuster and repeat the check until the number of clicks required is correct.
  8.  
  9. Raise the rear of the vehicle and support it safely. Release the handbrake and rotate each rear wheel to make sure the brakes are not dragging.
  10.  

1992-95 Montero

See Figures 1 and 2

  1. Pull the parking brake lever and pull up until the parking brakes will hold the vehicle from moving. The handle should only have to be pulled up 4-6 clicks.
  2.  
  3. If the handle stroke is not within the standard value range, make the following adjustments.
  4.  
  5. Loosen the adjuster to slacken the parking brake cable.
  6.  
  7. Remove the adjustment hole plug on the rear brake assemblies, and then use flat-tipped prytool to turn the adjuster in the direction of the arrow (the direction which expands the shoe) so that the disc will not rotate.
  8.  



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Fig. Fig. 1: Turn the adjuster in the direction of the arrow so that the disc will not rotate-1992-95 Montero



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Fig. Fig. 2: The adjustment components on 1992-95 Montero parking brakes

  1. Return the adjuster 3-4 notches in the direction opposite to the direction of the arrow.
  2.  
  3. Turn the adjusting nut to adjust the parking brake lever stroke to within the standard value range.
  4.  

If the number of brake lever notches engaged is less than the standard value, the cable has been pulled excessively. Be sure to adjust it to within the standard value.

  1. After making the adjustment, check to be sure that there is no play between the adjusting nut and the pin. Also check that the adjusting nut is securely held at the nut holder.
  2.  
  3. After adjusting the lever stroke, jack up the rear of the vehicle and support the vehicle with jackstands.
  4.  
  5. With the parking brake lever in the released position, tun the rear wheel to confirm that the rear brakes are not dragging.
  6.  
  7. Lower the vehicle back to the ground.
  8.  

Pick-up

See Figures 3, 4 and 5

  1. Pull the lever up with a force of about 66 lbs. (300 N) and count the number of notches or clicks. Correct number is 16 or 17.
  2.  
  3. If the number of clicks is incorrect, elevate and safely support the vehicle on stands; block the front wheels.
  4.  
  5. Under the vehicle, loosen the adjusting nuts to slacken each brake cable (one runs to each rear wheel from the equalizer).
  6.  
  7. Tighten the adjusting nuts just to the point of taking the slack out of the cable. Repeatedly pull and release the brake lever to adjust the rear brake shoes.
  8.  



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Fig. Fig. 3: Pull the parking brake handle out until the parking brakes will hold the vehicle from rolling-Pick-ups



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Fig. Fig. 4: Under the truck, tighten the nuts to the cables so that the equalizer forms a 90° angle with the bracket-Pick-up trucks



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Fig. Fig. 5: Remove the rear drums and check to make sure that the brake lever is just touching the brake shoe

  1. Tighten the adjusting nuts until the lever has the correct number of clicks.
  2.  

Make certain that the joint and equalizer are at right angles when the adjustment is finished. An angle other than 90° will cause uneven brake application.

  1. Fully release the parking brake lever and remove each rear wheel and brake drum. Make certain the brake lever is just touching the shoe.
  2.  


WARNING
If the parking brake cable is pulled too far, the adjuster lever will not fit the adjuster, resulting in faulty operation.

  1. Reinstall the drum and install the wheel.
  2.  
  3. Apply and release the parking brake once or twice. With the brake fully released, spin each rear wheel by hand and check for dragging brakes.
  4.  

REMOVAL & INSTALLATION



Pick-up
FRONT CABLE

See Figure 6

  1. Elevate and safely support the vehicle on stands.
  2.  
  3. Inside the vehicle, under the dash, identify and unplug the parking brake indicator switch. Remove the switch and bracket.
  4.  
  5. The end of the cable sheath is held in place by a snapring. Remove it. You are reminded that these snaprings tend to vanish if not removed carefully.
  6.  
  7. Lift the pawl from the ratchet and push the parking brake lever all the way in. In this position, the cable may be disconnected from the lever.
  8.  
  9. Under the vehicle, trace the cable and remove the clips and brackets holding it to the body.
  10.  
  11. Disconnect the cable from the lever assembly. Remove the cable from the vehicle. Don't damage the body grommet while removing it.
  12.  



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Fig. Fig. 6: Make certain to connect the front cable to the lever assembly correctly-Pick-up trucks

  1. Route the new cable into position. It's usually easier to attach the inner end to the lever first, then deal with the equalizer end. Loosen the adjusting nuts on the rear cables if necessary.
  2.  
  3. Once both ends are secured, install the clips and brackets holding the cable to the body.
  4.  
  5. Fit the rubber body grommet into place and make certain it is secure.
  6.  
  7. Install the snapring on the end of the cable.
  8.  
  9. Install the brake indicator switch in place and connect the wiring but do not final tighten the switch mount.
  10.  
  11. Adjust the parking brake lever stroke according to procedures given earlier in this section.
  12.  
  13. With the cable correctly adjusted, adjust the switch so that the warning light illuminates when the lever is pulled one notch. Tighten the switch mount.
  14.  

REAR CABLE

See Figures 7, 8 and 9

  1. Elevate and safely support the vehicle on stands.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the brake drum.
  6.  


CAUTION
Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from brake surfaces! When cleaning brakes, use commercially available brake cleaning fluids.

  1. At the equalizer, disconnect the return spring.
  2.  
  3. With the parking brake released, remove the adjusting nut from the cable to be removed. If only one cable is being removed, loosen the other adjuster to make the job easier. If both cables are being removed, loosen the nuts alternately and evenly.
  4.  
  5. Disconnect the brake cable from the brake shoe. You may find it easier to remove the shoes as a unit, then disconnect the cable.
  6.  



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Fig. Fig. 7: Rear parking brake cable removal and installation components-1983-95 Pick-ups



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Fig. Fig. 8: Use a box end wrench to remove the parking brake cable from the rear brake assembly-1983-95 Pick-up trucks



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Fig. Fig. 9: Adjusting the rear brake shoes to specification will allow the brakes to properly adjust themselves after installation-1987-95 Pick-ups

  1. Remove the cable from the backing plate. This can be made easier by feeding an offset box wrench (12mm) over the end of the cable and pushing it up until it reaches the stopper. Push on the wrench to release the tabs on the stopper and pull the cable free from behind the backing plate.
  2.  
  3. Remove the clips and brackets holding the cable to the body. Remove the cable from the vehicle.
  4.  
  5. When reinstalling, thread the cable into position. Make certain the stopper at the brake backing plate is securely fitted and the tab is engaged.
  6.  
  7. Install the cable end to the brake shoe. If the brakes were removed, reinstall them.
  8.  
  9. Turn the brake shoe adjuster to set the outside diameter of the shoes to 9.45-9.47 in. (240.0-240.5mm) for 1983-86 rear-wheel drive and 9.96-9.98 in. (253.0-253.5mm) for all other Pick-ups. This is an important dimension and must be observed.
  10.  
  11. Install the brake drum.
  12.  
  13. Connect the brake cable to the equalizer and tighten the adjuster nut just enough to remove slack from the cable.
  14.  
  15. Install the return spring correctly.
  16.  
  17. Install the rear wheels.
  18.  
  19. Adjust the parking brake lever travel according to instructions given previously in this section.
  20.  
  21. Lower the vehicle to the ground.
  22.  

Montero

See Figures 10 and 11

  1. Elevate and safely support the vehicle on stands.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the rear brake drum or brake disc.
  6.  


CAUTION
Brake pads and shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from brake surfaces! When cleaning brakes, use commercially available brake cleaning fluids.

  1. At the equalizer, remove the adjusting nut. Disconnect the cable to be replaced from the equalizer yoke. Remove the small heat shield from the cable.
  2.  
  3. At the rear wheel, remove the shoe return spring, the shoe retainer spring and the shoe hold-down pins. Remove the shoes as a unit, then disconnect the cable.
  4.  
  5. Remove the cable from the backing plate. This can be made easier by feeding a 0.47 in. (12mm) offset box wrench over the end of the cable and pushing it up until it reaches the stopper. Push on the wrench to release the tabs on the stopper and pull the cable free from behind the backing plate.
  6.  
  7. Remove the clips and brackets holding the cable to the body. Remove the cable from the vehicle.
  8.  
  9. When reinstalling, thread the cable into position. Make certain the stopper at the brake backing plate is securely fitted and the tab is engaged.
  10.  
  11. Install the cable end to the brake shoe. Install the brake shoes as an assembly and make certain the springs and retaining clips are properly placed.
  12.  



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Fig. Fig. 10: Parking brake cable removal and installation components-1983-91 Monteros



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Fig. Fig. 11: Parking brake cable removal and installation components-1992-95 Monteros

  1. Turn the brake shoe adjuster to set the outside diameter of the shoes to 9.96-9.98 in. (253.0-253.5mm) on rear drum brake systems. This is an important dimension and must be observed.
  2.  
  3. Install the brake drum or brake disc.
  4.  
  5. Connect the brake cable to the equalizer yoke. Install and tighten the adjuster nut just enough to remove slack from the cable.
  6.  
  7. Install the rear wheels.
  8.  
  9. Install the cable retaining clips and install the small cable heat shields.
  10.  
  11. Adjust the parking brake lever travel according to instructions given previously in this section.
  12.  
  13. Lower the vehicle to the ground.
  14.  

 
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