Mitsubishi Montero (2002-2004). Manual — part 1028

HYDRAULIC BRAKE BOOSTER (HBB)

TSB Revision

BASIC BRAKE SYSTEM

35A-137

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-135

.

.

<<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

HYDRAULIC BRAKE BOOSTER (HBB)

TSB Revision

BASIC BRAKE SYSTEM

35A-138

<<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.

ACX00676AB

A

ACX00677AB

MASTER CYLINDER
PISTON ASSEMBLY

POWER PISTON
ASSEMBLY

BUZZER

TSB Revision

BASIC BRAKE SYSTEM

35A-139

BUZZER

REMOVAL AND INSTALLATION

M1351016100018

BUZZER CHECK

M1351016200015

Check that the buzzer sounds when a battery is connected to
the buzzer as shown in the illustration.

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

GROUP 52A, Floor Console

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-117

.)

AC204378 AB

5.0 ± 1.0 N

·

m

44 ± 9 in-lb

BUZZER

ACX00680AB

FRONT DISC BRAKE ASSEMBLY

TSB Revision

BASIC BRAKE SYSTEM

35A-140

FRONT DISC BRAKE ASSEMBLY

REMOVAL AND INSTALLATION

M1351006000269

Required Special Tool:

• MB990520: Disc Brake Piston Expander

INSTALLATION SERVICE POINT

.

>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. To check the brake drag force after mounting the pad,

measure the hub torque in the advancing direction using a
spring scale with the pad is removed.

CAUTION

Do not allow any oil, grease or other contamination to con-
tact 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.

Pre-removal Operation
• Brake Fluid Draining

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

P.35A-

122

.)

ACX00681AB

113 ±

9 N

•

m

83 ±

7 ft-lb

30 ±

4 N

•

m

22 ±

3 ft-lb

2

2

1

3

4

N

N

REMOVAL STEPS

1. BRAKE HOSE CONNECTION
2. GASKET

>>A<<

3. DISC BRAKE ASSEMBLY
4. BRAKE DISC

ACX00683