Mitsubishi Outlander (2003+). Manual - part 261

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-15

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

REMOVAL AND INSTALLATION

M1351003700474

Pre-removal Operation

•

Air Intake Hose and Air Cleaner Removal (Refer to 

GROUP 15, Air Cleaner 

P.15-3

). <L.H. drive vehicles>

•

Brake Fluid Draining

Post-installation Operation

•

Brake Fluid Supplying and Air Bleeding (Refer to 

P.35A-7

).

•

Brake Pedal Adjustment (Refer to 

P.35A-4

).

•

Air Intake Hose and Air Cleaner Installation (Refer to 

GROUP 15, Air Cleaner 

P.15-3

). <L.H. drive vehicles>

AC309375

AC309375AB

3M ATD Part No. 8661 or equivalent

10

9

12 ± 2 N·m

14 ± 3 N·m

14

3

1

8

4

8

11

15 ± 2 N·m

15 ± 2 N·m

12

13

15

16

5

7

10 ± 2 N·m

16 ± 1 N·m

16

6

11

11

11

<L.H. drive vehicles>

<R.H. drive vehicles>

2000

2400

2

Master cylinder removal steps

1.

Brake fluid level sensor connector

<<A>>

>>D<<

2.

Reservoir protector <R.H. drive 
vehicles>

3.

Reservoir cap assembly

4.

Reservoir

5.

Brake fluid level sensor

6.

Reservoir hose <M/T>

>>C<<

7.

Reservoir hose

8.

Brake pipe connection

9.

Bracket <L.H. drive vehicles>

10. Master cylinder

Brake booster removal steps

1.

Brake fluid level sensor connector

8.

Brake pipe connection

9.

Bracket <L.H. drive vehicles>

10. Master cylinder

Master cylinder removal steps 

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-16

REMOVAL SERVICE POINT

<<A>> RESERVOIR PROTECTOR REMOVAL 
<R.H. DRIVE VEHICLES>

Disengage the claw of arrow 1 and arrow 2 in 
sequence, then remove the reservoir protector.

INSTALLATION SERVICE POINTS

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

>>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 to the 
brake booster. 

Standard value (A): 10.15 

−

 10.40 mm

NOTE: When a negative pressure of 66.7 kPa is 
not applied to the brake booster, the push rod 
protrusion amount (A) should be 8.85 - 9.10 mm.

>>B<<

•

Push rod protrusion amount check 
and adjustment

>>A<<

11. Vacuum hose (with built-in check 

valve)

12. Snap pin
13. Pin assembly
14. Brake booster
15. Sealer

Fitting removal steps

>>A<<

11. Vacuum hose (with built-in check 

valve)

16. Fitting

Brake booster removal steps 

AC309673AB

Reservoir protector

Reservoir

1

1

2

AC102457BD

A

Measuring distance A

Block gauge

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-17

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 push rod adjusting 
socket (MB991568) to turn the push rod while 
holding the rod spline with angle-nose pliers.

>>C<< RESERVOIR HOSE CONNECTION

Insert the reservoir hose with its paint mark facing 
front of the vehicle.

>>D<< RESERVOIR PROTECTOR INSTALLATION 
<R.H. DRIVE VEHICLES>

Install the reservoir protector with its arrow mark 
facing behind the vehicle.

AC200306AC

MB991568

Angle-nose pliers

Rod spline

AC200460AC

Paint mark

Paint mark

Master cylinder

AC309675AB

Reservoir protector

Reservoir

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER

BASIC BRAKE SYSTEM

35A-18

MASTER CYLINDER

M1351004200320

DISASSEMBLY AND REASSEMBLY

INSPECTION

M1351004300253

•

Check the inner surface of master cylinder body 
for rust or pitting.

•

Check the primary and secondary pistons for 
rust, scoring, wear or damage.

AC102644 AE

2

3

1

4

6

7

5

N

N

N

7

6

Master cylinder kit

Brake fluid: DOT 3 or DOT 4

4

5

3

6

5

Disassembly steps    

1. Spring pin
2. Nipple
3. Reservoir seal
4. Piston retainer
5. Primary piston assembly
6. Secondary piston assembly
7. Master cylinder body