Mitsubishi Galant 9G. Manual - part 409

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

TSB Revision

BASIC BRAKE SYSTEM

35A-28

>>B<< PUSH ROD PROTRUSION AMOUNT 
CHECK AND  ADJUSTMENT

1. Use the vacuum pump to measure dimension "A" applying a 

negative pressure of 66.7 kPa (19.7 inHg) to the brake 
booster. 

Standard value (A): 10.28 

− 10.52 mm (0.405 − 0.414 

inch)

NOTE: When a negative pressure of 66.7 kPa (19.7 inHg) is 
not applied to the brake booster, the push rod protrusion 
amount (A) should be 8.78 - 9.02 mm (0.346 

−

 0.355 inch).

2. If the protrusion amount is not within the standard value 

range, adjust the push rod length by turning the push rod. 
Use special tool MB991568 to turn the push rod while 
holding the rod spline with angle-nose pliers.

AC210713AB

A

MEASURING DISTANCE A

BLOCK GAUGE

AC210714 AB

MB991568

ANGLE-NOSE PLIERS

ROD SPLINE

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

TSB Revision

BASIC BRAKE SYSTEM

35A-29

MASTER CYLINDER

M1351004200375

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY SERVICE POINT

.

<<A>> BRAKE MASTER CYLINDER UNION 
RETAINER DISASSEMBLY

Remove the brake master cylinder union retainer while 
depressing the piston.

INSPECTION

M1351004300297

• Check the inner surface of master cylinder body for rust or 

pitting.

• Check the primary and secondary pistons for rust, scoring, 

wear or damage.

AC306545AB

1

3

5

6

4

N

N

N

6

5

MASTER CYLINDER KIT

BRAKE FLUID: DOT 3 OR DOT 4

3

4

1

5

4

2

N

N

DISASSEMBLY STEPS    

1. BRAKE MASTER CYLINDER TO 

FLUID RESERVOIR SEAL

2. BRAKE MASTER CYLINDER PIN 

<VEHICLES WITH ABS>

<<A>>

3. BRAKE MASTER CYLINDER UNION 

RETAINER

4. PRIMARY PISTON ASSEMBLY
5. SECONDARY PISTON ASSEMBLY
6. MASTER CYLINDER BODY

DISASSEMBLY STEPS     

AC000903

DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-30

DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351008000050

Required Special Tool:

• MB990520: Disc Brake Piston Expander

Pre-removal Operation
• Brake Fluid Draining

Post-installation Operation
• Brake Fluid Supplying and Air Bleeding (Refer to 

P.35A-16

).

AC305577AB

N

100 ± 10 N·m
74 ± 7 ft-lb

2

1

3

30 ± 4 N·m
22 ± 3 ft-lb

4

<FRONT>

AC305578AB

N

60 ± 5 N·m
45 ± 3 ft-lb

2

1

3

30 ± 4 N·m
22 ± 3 ft-lb

4

<REAR>

REMOVAL STEPS

• BRAKE FLUID DRAINING

1. BRAKE HOSE CONNECTION
2. GASKET
3. BRAKE CALIPER ASSEMBLY
4. BRAKE DISC

INSTALLATION STEPS

• BRAKE FLUID DRAINING

4. BRAKE DISC
3. BRAKE CALIPER ASSEMBLY
2. GASKET

1. BRAKE HOSE CONNECTION
• BRAKE FLUID SUPPLYING AND AIR 

BLEEDING (Refer to 

P.35A-16

.)

>>A<<

• BRAKE DRAG FORCE CHECK

INSTALLATION STEPS (Continued)

DISC BRAKE ASSEMBLY

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BASIC BRAKE SYSTEM

35A-31

INSTALLATION SERVICE POINT

.

>>A<<  BRAKE DRAG FORCE CHECK

1. In order to measure the brake drag force, measure the hub 

torque with the pads removed by the following procedure.
Use a spring scale  to measure the hub torque in the forward 
direction. Record hub torque with pads removed.

CAUTION

Do not let any oil, grease or other contamination get onto 
the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install 

the pad clips and the pads to the caliper support.

3. Clean the piston and insert into cylinder with special tool 

MB990520.

4. Be careful that the piston boot does not become caught, 

when lowering the caliper assembly and installing the lock 
pin bolt.

5. Check the brake drag force as follows.

(1) Start the engine and hold the brake pedal down for 5 

seconds. [Pedal depression force: approximately 200 N 
(45 pound)]

(2) Stop the engine.
(3) Turn the brake disc forward 10 times.

AC000906AG

SPRING SCALE

<FRONT>

AC305370

SPRING SCALE

AB

<REAR>

AC002027

MB990520

AB