Mitsubishi Galant (2004+). Manual - part 510

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

TSB Revision

BASIC BRAKE SYSTEM

35A-27

Required Special Tool:

• MB991568: Push Rod Adjusting Socket

INSTALLATION SERVICE POINTS

.

>>A<< BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert vacuum hose with its paint mark facing upward.

.

5.

BRAKE MASTER CYLINDER 
ASSEMBLY

6.

SPRING PIN

7.

BRAKE FLUID RESERVOIR 
ASSEMBLY

8.

MASTER CYLINDER FLUID 
RESERVOIR SEAL

9.

BRAKE FLUID LEVEL INDICATOR 
SWITCH

10. BRAKE FLUID RESERVOIR CAP

BRAKE BOOSTER VACUUM 
HOSE REMOVAL STEP

>>A<<

11. BRAKE BOOSTER VACUUM 

HOSE (WITH BUILT-IN CHECK 
VALVE)
BRAKE BOOSTER ASSEMBLY 
REMOVAL STEPS

1.

BRAKE FLUID LEVEL INDICATOR 
SWITCH CONNECTOR

2.

BRAKE TUBE CONNECTION

BRAKE MASTER CYLINDER 
ASSEMBLY AND BRAKE FLUID 
PROPORTIONING VALVE 
REMOVAL STEPS (Continued)

5.

BRAKE MASTER CYLINDER 
ASSEMBLY

>>B<<

•

PUSH ROD PROTRUSION 
AMOUNT CHECK AND 
ADJUSTMENT

>>A<<

11. BRAKE BOOSTER VACUUM 

HOSE

12. BRAKE BOOSTER PIN
13. BRAKE BOOSTER PIN 

ASSEMBLY

14. BRAKE BOOSTER NUT
15. BRAKE BOOSTER ASSEMBLY
16. BRAKE BOOSTER BODY SEAL

BRAKE BOOSTER ASSEMBLY 
REMOVAL STEPS (Continued)

AC305571

AB

PAINT MARK

PAINT MARK

VACUUM HOSE

<2.4L ENGINE>

<3.8L ENGINE>

VACUUM HOSE

PAINT MARK

PAINT MARK

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 DIS-
ASSEMBLY
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

TSB Revision

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)