Mitsubishi Eclipse 1990-1998 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



1990-94 Vehicles

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder reservoir cap, then use a clean turkey baster or equivalent to siphon out as much fluid as possible and place in a suitable container. Install the cap.
  4.  
  5. If equipped, detach the fluid level sensor connector.
  6.  
  7. Disconnect the brake lines from the master cylinder. A separate fluid reservoir is used. Plug the lines to prevent drainage.
  8.  
  9. Unfasten the 2 nuts securing the master cylinder to the brake booster, then remove the master cylinder.
  10.  



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Fig. Fig. 1: Exploded view of the master cylinder-to-power booster mounting

To install:
  1. Install master cylinder to the mounting studs and install the retaining nuts. Tighten the mounting nuts to 9 ft. lbs. (12 Nm).
  2.  
  3. Unplug and install the brake lines to the master cylinder.
  4.  
  5. Fill the reservoir to the proper level with clean DOT 3 brake fluid. Bleed the master cylinder.
  6.  
  7. If equipped, attach the fluid level sensor.
  8.  
  9. Apply the brake pedal and check for firmness. If the pedal is spongy,. air is present in the system. If air remains in the system, bleeding the entire system is required.
  10.  
  11. Adjust the brake pedal, as outlined later in this section.
  12.  
  13. Check the brakes for proper operation and leaks.
  14.  

1995-98 Vehicles

See Figures 2 through 12

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder reservoir cap, then use a clean turkey baster or equivalent to siphon out as much fluid as possible and place in a suitable container. Install the cap.
  4.  
  5. Disconnect and plug the lines from the brake master cylinder reservoir.
  6.  



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Fig. Fig. 2: Unfasten the master cylinder reservoir mounting bracket bolts



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Fig. Fig. 3: Unfasten the brake hose retaining clamps and disconnect the hose from the master cylinder



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Fig. Fig. 4: Detach the fluid level sensor connector, then remove the master cylinder reservoir

  1. Detach the fluid level sensor connector, unfasten the retainers, then remove the master cylinder reservoir.
  2.  
  3. For vehicles equipped with manual transaxle, remove the clutch master cylinder reservoir bracket.
  4.  
  5. For 2.0L non-turbo engines, perform the following:
    1. Disconnect the positive battery cable, then remove the battery.
    2.  
    3. Remove the relay mounting bolts.
    4.  
    5. Remove the washer tank mounting bolts and move the tank aside.
    6.  

  6.  



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Fig. Fig. 5: Unfasten the washer fluid reservoir tank mounting bolts...



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Fig. Fig. 6: ... then remove the tank and position it out of the way

  1. For 2.0L turbo and 2.4L engines, perform the following:
    1. Remove the centermember mounting bolts.
    2.  
    3. Remove the engine mount bracket.
    4.  
    5. Unfasten the A/C compressor mounting bolts and position the compressor aside, but do NOT disconnect the refrigerant lines.
    6.  
    7. Remove the A/C high pressure hose clamp, but do NOT disconnect the line.
    8.  
    9. Disconnect the power steering pressure hose, pipe and return pipe clamp mounting bolts. Do NOT disconnect the fluid lines.
    10.  

  2.  
  3. Disconnect and plug the brake lines from the master cylinder.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Use a flare nut wrench to disconnect and plug the brake lines from the master cylinder

  1. Unfasten the master cylinder-to-power booster retaining nuts, then remove the master cylinder from the vehicle.
  2.  



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Fig. Fig. 8: Unfasten the master cylinder-to-power booster retaining nuts ...



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Fig. Fig. 9: ... then remove the master cylinder assembly from the vehicle



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Fig. Fig. 10: Exploded view of the master cylinder and power brake booster-1995-98 vehicles

To install:
  1. Adjust the clearance (A) between the brake booster pushrod and the primary piston as follows:
  2.  



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Fig. Fig. 11: The brake booster pushrod and primary piston clearance (A) must be adjusted

    1. Calculate the clearance A from the B, C and D measurements, as shown in the accompanying figure. A equals B minus C minus D.
    2.  
    3. The clearance should be 0.256-0.335 in. (0.65-0.858mm). When brake booster negative pressure 9.7 psi (67 kPa) is applied, then clearance value will become 0.004-0.012 in. (0.1-0.3mm).
    4.  




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Fig. Fig. 12: Measuring the clearance of the pushrod-to-primary piston

  1. Install the master cylinder to the brake booster, then install the retaining nuts. Tighten the nuts to 7 ft. lbs. (10 Nm).
  2.  
  3. Install the master cylinder reservoir, securing the retainers.
  4.  
  5. Attach the fluid level sensor connector, then unplug and connect the fluid lines to the reservoir.
  6.  
  7. The remainder of installation is the reverse of the removal procedure. Fill the reservoir with the proper type and amount of DOT 3 brake fluid from a fresh, sealed container.
  8.  
  9. Bleed the brake system, as outlined later in this section.
  10.  
  11. Adjust the brake pedal, as outlined later in this section.
  12.  

BRAKE PEDAL ADJUSTMENTS



Brake Pedal Height

See Figures 13, 14 and 15

Measure the brake pedal height from the floor of the vehicle to the upper surface of the brake pedal. The distance should be 6.9-7.1 in (176-181mm). If the brake pedal height is incorrect, adjust as follows:

  1. Disconnect the stop lamp switch connector.
  2.  



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Fig. Fig. 13: Measure the brake pedal height at A and compare to specifications



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Fig. Fig. 14: Adjust the brake pedal height by increasing or decreasing the length of the operating rod



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Fig. Fig. 15: Inspect the clearance between the stop light switch and the brake pedal stop and compare to specifications

  1. Loosen the locknut on the base of the stop light switch and move the switch to a position where it does not contact the brake pedal.
  2.  
  3. Loosen the operating rod locknut. Adjust the height of the brake pedal by turning the operating rod using pliers. Once the desired pedal height is obtained, tighten the locknut on the operating rod.
  4.  
  5. Screw the stop light switch until the it contacts the brake pedal stopper. Turn switch in until the brake pedal just starts to move. At this point, return (loosen) the stoplight switch 1 / 2 -1 turn and secure in this position by tightening the locknut. In this position, the distance between the lower stop light switch case and the brake pedal stop should be 0.02-0.04 in. (0.5-1.0mm).
  6.  
  7. Connect the electrical connector to the stop light switch.
  8.  
  9. Check to be sure that the stop lights are not illuminated with no pressure on the brake pedal.
  10.  
  11. Without starting the vehicle, depress the brake pedal. If the brake light switch is properly connected, the brake lights will illuminate.
  12.  

Brake Pedal Free-Play

See Figure 16

  1. With the engine off, depress the brake pedal fully several times to evacuate the vacuum in the booster.
  2.  



Click image to see an enlarged view

Fig. Fig. 16: Inspect brake pedal free-play

  1. Once all the vacuum assist has been eliminated, press the brake pedal down by hand and confirm that the amount of movement before resistance is felt is within 0.1-0.3 in. (3-8mm).
  2.  
  3. If the free-play is less than desired, confirm that the brake light switch is in proper adjustment.
  4.  
  5. If there is excessive free-play, look for wear or play in the clevis pin and brake pedal arm. Replace worn parts as required and recheck brake pedal free-play.
  6.  

 
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