Mitsubishi Montero (2004+). Manual - part 1035

 

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Mitsubishi Montero (2004+). Manual - part 1035

 

 

HYDRAULIC BRAKE BOOSTER (HBB)

TSB Revision

BASIC BRAKE SYSTEM

35A-139

3. Using special tool MB991926, remove the accumulator.
4. Remove the o-ring installed between the accumulator and 

the HBB.

5. Install a new o-ring to a new accumulator.
6. Using special tool MB991926, install the new accumulator to 

the HBB. The tightening torque of the accumulator is 54 

± 5 

N

⋅m (40 ± 4 ft-lb).

7. Fill the HBB brake system with brake fluid and bleed the 

HBB brake system (Refer to 

P.35A-125

).

8. Carry out the function and operation check of power supply 

system (Refer to 

P.35A-120

).

9. Erase HBB diagnostic trouble code (Refer to 

P.35A-13

).

10.Dispose of the removed accumulator (Refer to 

P.35A-139

).

ACCUMULATOR DISPOSAL

M1351015900011

WARNING

Do not disassemble, throw into fire, cut, weld, drop, 
or shock the accumulator without purging filled gas.

1. Fix the accumulator on a vice as illustrated.

2. Punch in the area shown in the illustration to fix the drilling 

position.

3. Set a drill [diameter 

φ 4 mm (φ 0.16 in)] on the drill motor.

AC204060

AB

MB991926

ACCUMULATOR

AC204540

AC204541AB

Φ50 mm

Φ2.0 in

HYDRAULIC BRAKE BOOSTER (HBB)

TSB Revision

BASIC BRAKE SYSTEM

35A-140

WARNING

Wear protective glasses during drilling to protect you 
from scattered chips caused by spouting gas.

4. Using a drill motor, drill a hole on the accumulator to purge 

filled gas.
NOTE: 

.

There is no danger of accumulator burst due to drilling 
work.

You can hear purging sound of gas as soon as a hole is 
made on the accumulator.

The filled gas is nitrogen, which is colorless, odorless 
and harmless.

5. Dispose of the accumulator in compliance with Federal, 

state, and local laws.

DISASSEMBLY AND ASSEMBLY

M1351010800064

AC204539

AC204377 AC

1

2

1.7 ± 0.3 N

m

15 ± 2.6 in-lb

25.5 ± 5.1 N

m

19 ± 3 ft-lb

19

21

20

22

23

3

4

BRAKE FLUID: DOT3 OR DOT4

24

5

6

7

8

9

15

15.2 ± 3 N

m

11 ± 2 ft-lb

3.0 ± 0.5 N

m

26 ± 4 in-lb

1.7 ± 0.1 N

m

15 ± 1 in-lb

14

13

12

11

18

17

16

10

7.8 ± 1.5 N

m

69 ± 13 in-lb

7.8 ± 1.5 N

m

69 ± 13 in-lb

1.7 ± 0.3 N

m

15 ± 2.6 in-lb

54 ± 5 N

m

40 ± 4 ft-lb

N

N

N

N

11.8 ± 2.3 N

m

104 ± 20 in-lb

HYDRAULIC BRAKE BOOSTER (HBB)

TSB Revision

BASIC BRAKE SYSTEM

35A-141

Required Special Tools:

• MB991926: Accumulator Wrench

• MB991620: Valve Spring Compressor Adapter

DISASSEMBLY SERVICE POINTS

.

<<A>> ACCUMULATOR REMOVAL
Using special tool MB991926, remove the accumulator. For 
disposing of the accumulator, refer to 

P.35A-139

.

.

<<B>> SECURING THE HBB
Secure the HBB on a vice as shown in the illustration, using 
spacers and special tool MB991620.

.

DISASSEMBLY STEPS

1.

RESERVOIR CAP

2.

RESERVOIR ASSEMBLY

3.

GROMMET

<<A>>

4.

ACCUMULATOR

5.

O-RING

6.

SPRING

7.

SILENT TUBE

8.

HOSE

9.

HBB BRAKE TUBE

10. LEAD WIRE
11. WASHER
12. BUSHING
13. COLLAR
14. PIN
15. BRACKET
16. BRACKET

17. BUSHING
18. PUMP MOTOR
19. CLEVIS
20. BOOT

<<B>>

SECURING THE HBB

<<C>>

21. SNAP RING

<<C>>

22. POWER PISTON ASSEMBLY

<<C>>

23. MASTER CYLINDER PISTON 

ASSEMBLY

24. MASTER CYLINDER AND 

HYDRAULIC UNIT ASSEMBLY

DISASSEMBLY STEPS (Continued)

AC204379AB

MB991926

ACX00675AB

MASTER CYLINDER

AND HYDRAULIC UNIT

ASSEMBLY

SPACER

MB991620

BUZZER

TSB Revision

BASIC BRAKE SYSTEM

35A-142

<<C>> SNAP RING/POWER PISTON ASSEMBLY/MASTER 
CYLINDER PISTON ASSEMBLY REMOVAL
1. Press-in the push rod of the power piston assembly, and 

remove the snap ring using a precision minus-slot 
screwdriver or similar tool.
NOTE: If it is difficult to remove the snap ring, push the snap 
ring from the hole ("A" in the illustration) on the cylinder 
body.

CAUTION

Pull out the cylinder carefully so that the inner diameter of 
the cylinder is not damaged.
2. Pull to remove the power piston assembly and the master 

cylinder piston assembly straight from the body.

BUZZER

REMOVAL AND INSTALLATION

M1351016100018

ACX00676AB

A

ACX00677AB

MASTER CYLINDER
PISTON ASSEMBLY

POWER PISTON
ASSEMBLY

Pre-removal Operation
• Indicator Panel, Lower Center Panel Removal (Refer to 

GROUP 52A, Floor Consol

P.52A-7

.)

Post-installation Operation
• Indicator Panel, Lower Center Panel Installation (Refer to 

GROUP 52A, Floor Console 

P.52A-7

.)

• Buzzer Operation Check (Refer to 

P.35A-120

.)

AC204378 AB

5.0 ± 1.0 N

·

m

44 ± 9 in-lb

BUZZER

 

 

 

 

 

 

 

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