SUBJECT:
BRAKE BOOSTER REPLACEMENT
- SAFETY RECALL CAMPAIGN 		No: SR-05-002
DATE: May, 2005
MODEL: 2006 Eclipse
CIRCULATE TO: [ ] GENERAL MANAGER [X] PARTS MANAGER [X] TECHNICIAN
[X] SERVICE ADVISOR [X] SERVICE MANAGER [X] WARRANTY PROCESSOR [ ] SALES MANAGER



PURPOSE
Some affected vehicles may have a defective brake booster. The booster body could separate due to improper crimp joints, resulting in a total loss of brake system performance. If inspection by MMNA or Bosch personnel determines it necessary to replace the brake booster (or if instructed to replace the brake booster without MMNA/Bosch inspection due to remote location where inspection is not possible), follow the replacement instructions in this bulletin.

NOTE: If your replacement part already has a master cylinder installed, remove the master cylinder from the assembly and discard. Use the original master cylinder, so that brake system bleeding is not necessary.

NOTE: The brake booster installation and removal procedures in the 2006 Eclipse service manual are incorrect. A Service Manual Revision will be issued soon.

AFFECTED VEHICLES
2006 Eclipse models produced before 5/23/05

PROCEDURE
Before starting this campaign procedure, CHECK ON THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

1.Record the customer's audio system settings.

2.V6 MODELS ONLY: Remove the air cleaner resonator.

3.V6 MODELS ONLY: Remove the strut bar from the rear of the engine compartment.



4.Remove the battery and battery tray.

5.Remove the vacuum hose from the brake booster.













6.M/T MODELS ONLY: Install a clamp to the clutch master cylinder hose. Then remove the hose from the clutch master cylinder.









Use care to prevent damaging the nipple on the clutch master cylinder during hose removal.

7.Carefully pry the top two metal brake lines from the white plastic clips attached to the bulkhead. Use a small flat blade screwdriver to gently lift the plastic tab. Then remove the brake line from the clip.









8.Remove the master cylinder from the brake booster.

IMPORTANT: Do not disconnect the brake lines from the master cylinder.

NOTE: If your replacement part already has a master cylinder installed, remove the master cylinder from the assembly and discard. Use the original master cylinder, so that brake system bleeding is not necessary.




9.Inside the vehicle, under the instrument panel:

a.Remove the C-clip and pivot pin securing the brake booster push rod to the brake pedal.

b.Remove the four 12 mm nuts from the brake booster mounting studs.

10.In the engine compartment, move the master cylinder away from the brake booster.
IMPORTANT: Do not dislodge the master cylinder plunger sleeve or O-ring.

11.Carefully remove the brake booster from the bulkhead. Do not damage the brake booster body seal.

12.Replace the brake booster, using the parts listed in the PARTS INFORMATION section of this bulletin.
Torque the mounting nuts to 13 + 2 Nm (104 + 25 in/lb).


13.Reinstall the C-clip and pivot pin to secure the booster push rod to the brake pedal.

14.V6 MODELS ONLY: Reinstall the strut bar. Torque to 12 + 2 Nm (102 + 22 in/lb).


15.Reattach the brake lines to the plastic clip at the bulkhead.

16.Reinstall the master cylinder. Torque the 13 mm nuts to 22 + 5 Nm (17 + 4 ft/lbs).

17.Reinstall the vacuum hose to the brake booster.

18.Reinstall the battery tray and battery.

19.M/T MODELS ONLY: Perform clutch bleeding as follows:

a.Connect a hose with a bottle to the bleeder screw.
b.Open the bleed nipple.
c.Depress the clutch pedal slowly. Open the bleeder screw to let air and brake fluid out. Then close the bleeder screw. Release the clutch pedal. Repeat until only brake fluid and no air comes out.
d.Check that the brake fluid reservoir level stays between the "MAX" and "MIN" marks throughout the clutch bleeding process.
e.Replenish the fluid as necessary. Use Mitsubishi Brake Fluid p/n MZ311987.

20.V6 MODELS ONLY: Reinstall the air cleaner resonator.

21.Reset the customer's audio system settings.

22.Confirm proper brake, clutch (M/T models), and window operation.

PARTS INFORMATION
Use the Genuine Mitsubishi Parts listed below.

Description Model Part Number
Brake Booster Assembly 2006 Eclipse A/T 4630A019
Brake Booster Assembly 2006 Eclipse M/T 4630A020


WARRANTY INFORMATION

IMPORTANT: Recall claims for the replacement of the brake booster may only be performed if prior authorized by MMNA. If approved, MMNA will have automatically shipped you the required brake booster replacement part.

Enter the recall claim over the MDL.

Labor Times: (Enter only time for applicable transmission equipped vehicle)

Automatic Transmission Models: 1.5 hours
Manual Transmission Models: 2.0 hours

Allowable Parts:
Brake Boosters: All Prior Approved Replacements will generate a forced shipment of the needed part. No dealer ordering is necessary.

Automatic Transmission Models: 4630A019
Manual Transmission Models: 4630A020

Brake / Clutch Fluid: MZ311987












Mitsubishi Motors North America, Inc.


The information contained in this bulletin is subject to change. For the latest version of this document, go to the Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).