Mitsubishi Outlander 2003-06

Master Cylinder

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Overhaul



  1. Remove the clutch master cylinder from the vehicle, as outlined earlier in this section.
  2.  
  3. Disassemble the following components:
    WARNING
    Do not disassemble the piston assembly.



    Piston stopper ring
     
    Piston assembly
     



    Pushrod assembly
     
    Boot
     
    Spring pin
     
    Nipple
     
    Seal
     
    Master cylinder body

    Click image to see an enlarged view

    Fig. Exploded view of the clutch master cylinder

     

  4.  

To assemble:

  1. Assemble the following components:

    Master cylinder body
     
    Seal
     
    Nipple
     
    Spring pin
     
    Boot
     
    Pushrod assembly. Set the length of the pushrod assembly to the dimension shown in the accompanying illustration to make the adjustment of the clutch pedal easier.

    Click image to see an enlarged view

    Fig. Set the length of the pushrod assembly to the dimension shown to make the adjustment of the clutch pedal easier

     
    Piston assembly.
     
    Piston stopper ring
     

  2.  
  3. Install the clutch master cylinder in the vehicle.
  4.  
  5. Bleed the clutch master cylinder as follows:
    1. Disconnect the brake tube clamp and remove the brake master cylinder with the brake tubes connected.
    2.  
    3. Remove the brake fluid reservoir with the hoses connected.
    4.  
    5. Connect a hose with a bottle to the bleeder screw.
    6.  
    7. Open the bleed nipple.
    8.  
    9. Depress the clutch pedal slowly. Open the bleeder screw to let air and brake fluid out. Close the bleeder screw. Release the clutch pedal. Repeat until only brake fluid and no air comes out.
    10.  
    11. Check that the brake fluid reservoir level stays between "MAX" and "MIN" marks throughout the clutch bleeding process.

      Click image to see an enlarged view

      Fig. Bleeding the clutch master cylinder

    12.  

  6.  
  7. Adjust the clutch pedal, as follows:
    1. Measure the clutch pedal height. The standard value (A) is 201-205mm (7.9-8.1 inch).

      Click image to see an enlarged view

      Fig. Measure the clutch pedal height (A)

    2.  
    3. Measure the clutch pedal clevis pin play. The standard value (B) is 1-3 mm (0.04-0.12 inch).
      WARNING
      Do not push in the master cylinder pushrod at this time, otherwise the clutch will not operate properly.



      Click image to see an enlarged view

      Fig. Measure the clutch pedal clevis pin play (B)

    4.  
    5. If the clutch pedal height and clutch pedal clevis pin play are not within the standard value, loosen the setting nut to adjust the clutch pedal height and clevis pin play to the standard value.

      Click image to see an enlarged view

      Fig. If the clutch pedal height and clutch pedal clevis pin play are not within the standard value, loosen the setting nut to adjust the clutch pedal height and clevis pin play to the standard value

    6.  

  8.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the clutch fluid.
  6.  
  7. Remove the air cleaner body.

    Click image to see an enlarged view

    Fig. Exploded view of the air cleaner assembly

  8.  
  9. Remove the clutch pedal, as follows:
    1. Remove the instrument panel undercover.
    2.  
    3. Remove the hook lock release handle.
    4.  
    5. Remove the instrument panel assembly, as outlined in the Body Section.
    6.  
    7. Remove the cowl side trim.
    8.  
    9. Refer to the accompanying illustration for the remainder of the clutch pedal removal.

      Click image to see an enlarged view

      Fig. Clutch pedal removal and installation

    10.  

  10.  
  11. Disconnect the clutch hose connection (transmission side).
  12.  
  13. Disconnect the reservoir hose.
  14.  
  15. Remove the retainer plate.
  16.  
  17. Remove the clutch master cylinder and clutch hose assembly.
  18.  
  19. Remove the eye bolt.
  20.  
  21. Remove the gasket.
  22.  
  23. Remove the clutch hose.
  24.  
  25. Remove the clutch master cylinder, as follows:
    1. Disconnect the brake tube clamp, then remove the brake master cylinder with the brake tubes connected.
    2.  
    3. Remove the brake fluid reservoir with the hoses connected.
    4.  
    5. Remove the clutch master cylinder.
    6.  

  26.  
  27. Remove the gasket (sealer).
  28.  
  29. Inspect the master cylinder and hoses for leaks. Check the clutch hose or tubes for cracking or clogging.

    Click image to see an enlarged view

    Fig. Exploded view of the clutch master cylinder and related components

  30.  

To install:

  1. Position a new gasket (sealer).
  2.  
  3. Install the clutch master cylinder in the reverse of the removal procedure.
  4.  
  5. Connect the clutch hose.
  6.  
  7. Install the gasket.
  8.  
  9. Install the eye bolt and tighten to 19-25 ft. lbs. (26-34 Nm).
  10.  
  11. Install the clutch hose and master cylinder assembly into the vehicle.
  12.  
  13. Install the retainer plate.
  14.  
  15. Connect the reservoir hose.
  16.  
  17. connect the transmission side clutch hose connection.
  18.  
  19. Install the clutch pedal in the reverse of the removal procedure.
  20.  
  21. Fill the clutch master cylinder reservoir with the proper amount of DOT 3 or DOT 4 Brake fluid. Do NOT use any other type of fluid.
  22.  
  23. Bleed the clutch master cylinder as follows:
    1. Disconnect the brake tube clamp and remove the brake master cylinder with the brake tubes connected.
    2.  
    3. Remove the brake fluid reservoir with the hoses connected.
    4.  
    5. Connect a hose with a bottle to the bleeder screw.
    6.  
    7. Open the bleed nipple.
    8.  
    9. Depress the clutch pedal slowly. Open the bleeder screw to let air and brake fluid out. Close the bleeder screw. Release the clutch pedal. Repeat until only brake fluid and no air comes out.
    10.  
    11. Check that the brake fluid reservoir level stays between "MAX" and "MIN" marks throughout the clutch bleeding process.

      Click image to see an enlarged view

      Fig. Bleeding the clutch master cylinder

    12.  

  24.  
  25. Adjust the clutch pedal, as follows:
    1. Measure the clutch pedal height. The standard value (A) is 201-205mm (7.9-8.1 inch).

      Click image to see an enlarged view

      Fig. Measure the clutch pedal height (A)

    2.  
    3. Measure the clutch pedal clevis pin play. The standard value (B) is 1-3 mm (0.04-0.12 inch).
      WARNING
      Do not push in the master cylinder pushrod at this time, otherwise the clutch will not operate properly.



      Click image to see an enlarged view

      Fig. Measure the clutch pedal clevis pin play (B)

    4.  
    5. If the clutch pedal height and clutch pedal clevis pin play are not within the standard value, loosen the setting nut to adjust the clutch pedal height and clevis pin play to the standard value.

      Click image to see an enlarged view

      Fig. If the clutch pedal height and clutch pedal clevis pin play are not within the standard value, loosen the setting nut to adjust the clutch pedal height and clevis pin play to the standard value

    6.  

  26.  
  27. Install the air cleaner box.
  28.  
  29. Connect the negative battery cable.
  30.  

 
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