SUBJECT: BRAKE MASTER CYLINDER REPLACEMENT - SAFETY RECALL CAMPAIGN

No: SR-05-003

DATE: June, 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 master cylinder. An internal seal may have been installed incorrectly, allowing brake fluid to bypass during braking, resulting in partial reduction in braking function, which could lead to a crash. Dealers are instructed to replace the master cylinder on all affected vehicles, using the master cylinder repair kit listed in the PARTS INFORMATION section of this bulletin. The master cylinder repair kit contains the master cylinder assembly, O-ring, two attachment nuts, and a "CAUTION" sheet (shown in Attachment A at the end of this bulletin).

AFFECTED VEHICLES
2006 Eclipse models produced before 6/10/05



CUSTOMER NOTIFICATION
A letter will be sent to all owners of affected vehicles, asking them to bring their vehicle to their selling Mitsubishi Motors dealer to have the brake master cylinder replaced. A copy of the customer notification letter appears later in this bulletin. Dealers are also asked to contact their customers (by phone, e-mail, or fax), asking them to bring their vehicle to the dealership for this repair.

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

1.Record the customer's audio system settings, so you can re-set them after the battery is reconnected.

2.Be sure both windows are completed closed. This prevents the power windows from losing their short stroke memory.

3.Remove the strut tower bar (3.8L engine only).

4.Remove the battery.

5.Remove the brake fluid reservoir cap and filter.

Be careful during this procedure to prevent spilling any brake fluid on painted surfaces.

6.Drain the brake fluid from the master cylinder and dispose of properly.

7.Disconnect the brake fluid level indicator switch connector.

8.Disconnect the clutch reservoir hose.

9.Disconnect the brake lines, using a line wrench to prevent damaging the attachment nuts.

10.Remove the brake master cylinder:

a.Disconnect the brake booster vacuum hose.

b.Remove the two 13 mm attachment nuts and discard them.

11.Replace the master cylinder assembly, using the master cylinder repair kit listed in the PARTS INFORMATION section of this bulletin.

NOTE: The master cylinder repair kit contains the master cylinder assembly, O-ring, two attachment nuts, and a "CAUTION" sheet (shown in Attachment A at the end of this bulletin). Remove the foam piston protector before installing.



Take care to prevent damaging the master cylinder piston. If the piston becomes dislodged, discard the master cylinder. Do not attempt to reinsert the piston.

Be sure the O-ring provided in the kit is properly installed.

a.Use the O-ring and attachment nuts provided in the master cylinder assembly kit. Tighten the attachment nuts to 22 + 5 Nm (17 + 4 ft/lb).

NOTE: A small amount of brake fluid residue in the brake booster is normal.

12.Reinstall the brake booster vacuum hose.

13.Connect the clutch reservoir hose.

14.Connect the brake fluid level indicator switch connector.

15.Fill the master cylinder reservoir with brake fluid. Use Mitsubishi Brake Fluid p/n MZ311987.

16.Thoroughly bleed the master cylinder and brake lines as follows:

a.Press and hold the brake pedal. b.Have another person cover the master cylinder outlets with their fingers. c.Release the brake pedal. d.Repeat steps a. through c. at least three times, holding the pedal to the floor the third time. Ensure that all air is removed.

17.Tighten the brake line attachment nuts to 15 + 2 Nm (12 + 1 ft/lbs).

18.Use brake cleaner to remove any brake fluid on the battery tray.

19.Reinstall the battery.

20.Reinstall the strut tower bar (3.8L engine only).

21.Start the engine and bleed the air in the brake lines at each caliper, in the sequence shown.

22.Thoroughly bleed the clutch as follows (M/T models only):

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.

23.Replenish the fluid as necessary. Use Mitsubishi Brake Fluid p/n MZ311987. The master cylinder reservoir should be filled with brake fluid between "MIN" and "MAX" marks.

24.Reinstall the brake fluid reservoir cap and filter.

25.Reset the customer's audio system settings.

26.CANADA VEHICLES ONLY: The outside temperature display defaults to Fahrenheit degrees when power is interrupted, such as battery disconnection. To change the display to Celsius degrees, push in the "H" and "M" buttons at the same time, and hold for 10 seconds.

27.The 6-disc CD player will automatically conduct a self-check after the battery is reconnected and the ignition key is turned to ON. This will cause the CD player to cycle through each of the CD trays and make an unusual noise for about 30 seconds.

Inspect the CD player as described below. If audio unit replacement is necessary, exchange units are available from your normal Mitsubishi Audio Exchange Centers (Yamada, RSSC, or H&R). If audio unit exchange is necessary, normal warranty exchange procedures and requirements apply.

CD PLAYER INSPECTION PROCEDURE
a.Engage the IOD fuse.
b.Turn the ignition key to the ON position.
c.The CD changer will initialize for about 15 seconds. If error message "E 03" is displayed on the center display, exchange the audio unit.
d.If no error is displayed, press the "LOAD EJECT" button. Then press the "6" button. Wait for the "Ready" light to illuminate constantly. The "Ready" light flashes until the 6th slot is in position. Then insert a CD.
e.Confirm the CD plays with no problem.
f.To remove the CD, press the "LOAD EJECT" button, then press the "6" button. If error message "E 03" is displayed on the center display, exchange the audio unit.

28.Ensure that the auto down feature on the driver's window, and the short stroke feature on both windows are operational. If necessary, reinitialize the short stroke memory as follows:
DOOR GLASS "SHORT STROKE" INITIALIZATION PROCEDURE
a.Close the door.
b.Use the power window switch to fully close the window.
c.Release the power window switch.
d.Pull up the power window switch again and hold it for a few seconds until a soft "click" is heard.

29.THROTTLE BODY INITIALIZATION PROCEDURE
Initialize the throttle body as follows: Turn the ignition switch to ON, then to OFF. Wait for at least 10 seconds before turning the key back to ON.

PARTS INFORMATION
A supply of master cylinder kits will be automatically shipped to each dealer, based on sold, in-transit, and in-stock inventory as of 6/22/05. Additional kits can be ordered through the normal parts system, but will be on manual allocation.
Each kit contains a master cylinder assembly, O-ring, two attachment nuts, and a "CAUTION" sheet.

Description

Model

Part Number

Dealer Net

Brake Master Cylinder Kit

2006 Eclipse A/T

4625A027KT

$ 38.25

Brake Master Cylinder Kit

2006 Eclipse M/T

4625A028KT

$ 38.25

Mitsubishi Brake Fluid

-

MZ311987

-

WARRANTY INFORMATION

Campaign Operation Number: C0503KXX
Enter this campaign claim over the MDL, using the Recall claim type option.
Sample recall claim screens are shown on the following pages.

Labor Time (for both A/T and M/T models): 1.3 hrs.

Allowable Parts:
Master Cylinder Kit (automatic transmission models) - p/n 4625A027KT
Master Cylinder Kit (manual transmission models) - p/n 4625A028KT
Mitsubishi Brake Fluid - p/n MZ311987 (up to 2 bottles)

Mitsubishi Motors North America, Inc.








ATTACHMENT A