Mitsubishi Outlander GS45X. Manual - part 1550

BRAKE PEDAL

TSB Revision

BASIC BRAKE

35A-29

INSPECTION

STOPLIGHT SWITCH CHECK

M1351008900633

CAUTION

Do not apply grease or lubricant to the switch and the 
switch installation section to avoid malfunction of the 
switch. In addition, do not use gloves which have grease 
on them.
Check for continuity between the terminals of the switch.

BRAKE PEDAL DISTORTION CHECK

M1351016300205

1. Place the brake pedal assembly on a level surface as shown 

in the figure, and set the distance from the centre of the pin 
assembly mounting hole to the level surface to 97 mm (3.82 
inch). Make sure that the dimension A in the figure (distance 
from the pedal pad surface to the level surface) is within the 
standard value.

Standard value (A): 250 

− 254 mm (9.8 − 10.0 inch)

2. When dimension A is not within the standard value, replace 

the brake pedal assembly.

Check 
condition

Terminal 
connector of 
tester

Normal 
condition

At free position 1 

− 2 (for 

stoplight switch)

Continuity 
exists

 

(2 

Ω or less)

3 

− 4 (for cruise 

control)

No continuity

Press the 
plunger from the 
edge of the 
outer case by 
the dimension 
shown in the 
figure.

1 

− 2 (for 

stoplight switch)

No continuity

3 

− 4 (for cruise 

control)

Continuity 
exists

 

(2 

Ω or less)

AC900541AB

No continuity

For stoplight switch

For cruise control

Continuity

Continuity

No continuity

6.0 ± 0.5 mm 
(0.24 ± 0.01 in)

3.6 ± 0.4 mm 
(0.14 ± 0.01 in)

AC507986AB

97mm
(3.82 inch)

A

Brake pedal assembly

Pin assembly
center hole

Pedal pad center part

Flat surface

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

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BASIC BRAKE

35A-30

MASTER CYLINDER ASSEMBLY AND 

BRAKE BOOSTER ASSEMBLY

REMOVAL AND INSTALLATION

M1351003701659

CAUTION

Do not touch the push rod in the brake booster 
because it is already adjusted.

Pre-removal operation
• Brake Fluid Draining

• Bottom Cover Assembly (driver's seat) Removal (Refer to 

GROUP 52A 

− Instrument Panel Assembly 

P.52A-2

).

• Air Cleaner Body Removal (Refer to GROUP 15 − Air 

Cleaner 

P.15-4

 <2.4L Engine> or 

P.15-5

 <3.0L Engine>).

Post-installation operation
• Air Cleaner Body Installation (Refer to GROUP 15 − Air 

Cleaner 

P.15-4

 <2.4L Engine> or 

P.15-5

 <3.0L Engine>).

• Brake Fluid Refilling and Air Bleeding (Refer to 

P.35A-20

).

• Bottom Cover Assembly (driver's seat) Installation (Refer 

to GROUP 52A 

− Instrument Panel Assembly 

P.52A-2

).

AC709978

14

N

N

1

3

3

2

7

8

10

11

12

5

6

9

13

15

17

16

AB

25 ± 4 N·m
18 ± 3 ft-lb

N

4

14 ± 3 N·m
11 ± 2 ft-lb

16 ± 3 N·m
12 ± 2 ft-lb

Master cylinder removal steps 

1.

Brake fluid level switch connector 
connection

2.

Reservoir cap

3.

Brake pipe connection

>>

B

<< •

Bleeding of master cylinder 
assembly (only at installation)

4.

Master cylinder mounting nuts

5.

Reservoir assembly and master 
cylinder assembly

6.

Torx bolt

7.

Reservoir assembly

8.

O-ring

9.

Master cylinder assembly

Brake booster removal steps 

1.

Brake fluid level switch connector 
connection

3.

Brake pipe connection

>>

B

<< •

Bleeding of master cylinder 
assembly (only at installation)

4.

Master cylinder mounting nuts

5.

Reservoir assembly and master 
cylinder assembly

>>

A

<< 10. Vacuum hose connection

11. Hose clip
12. Check valve
13. Snap pin
14. Pin assembly
15. Brake booster mounting nut
•

Strut tower bar (Refer to GROUP 
42A, Strut Tower Bar 

P.42A-12

.)

16. Brake booster assembly
17. Seal

Brake booster removal steps 

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

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BASIC BRAKE

35A-31

<VACUUM HOSE AND VACUUM PIPE>

AC709979

<3.0L Engine>

3

4

6

1

2

2

2

1

2

7

4

5

5

<2.4L Engine>

13 ± 2 N·m
111 ± 22 in-lb

11 ± 1 N·m
98 ± 4 in-lb

AB

Removal steps 

>>

A

<< 1.

Vacuum hose

2.

Hose clip

>>

A

<< 3.

Vacuum hose <2.4L Engine>

4.

Hose clip <2.4L Engine>

5.

Emission vacuum hose connection 
<2.4L Engine>

6.

Vacuum pipe assembly <2.4L 
Engine>

7.

Clamp <3.0L Engine>

Removal steps (Continued)

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY

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BASIC BRAKE

35A-32

INSTALLATION SERVICE POINTS

.

>>A<< VACUUM HOSE INSTALLATION

Align the mark as shown in the figure to assemble the vacuum 
hose.

.

>>B<< BLEEDING OF MASTER CYLINDER 
ASSEMBLY

When removed the master cylinder assembly, bleed the master 
cylinder in the following procedure to make bleeding of the 
brake pipeline easier (When no brake fluid is in the master cyl-
inder).
1. Fill the brake fluid reservoir with the brake fluid.
2. Depress and hold the brake pedal.

AC613196

AH

<2.4L Engine>

A

B

C

View A

View B

D

Paint mark

View C

Paint mark

Paint mark

Paint mark

View D

AC607649

Vacuum hose

AF

<3.0L Engine>

Paint mark

Paint mark