How to repair a Faulty ABS / HBB Motor Pump on a Pajero / Montero / Shogun

[basil]

Top effort champ .

[Ricstar]

Great post.
I also recently had issues with my HBB. In my case BHSS in Capalaba, a local hydraulics specialist reconditions Pajero HBB's. Mine was removed, reconditioned and refitted for just over $1000.
My issue was sinking brake pedal, which ended up being the master cylinder corroded. Now that should not happen on a 2003 Paj with only 125k on the clock, but they advised that it had DOT3 in it and it MUST be DOT4. Using DOT 3 with lower boiling temp builds up moisture and therefore master cylinder prematurely corroded. I used to have a well known brake place bleed my brakes every 2 years. Also 500ml is not enough to flush all the fluid, so if someone quotes $60 for a flush, walk away.

Refill the reservoir with clean DOT3 or DOT4 brake fluid (I used DOT4).

Anyhow, It was resleaved and I believe the accumulator motor also rewound like yours was (sent off to a local Auto Electrician who does the accumulator reconditioning) and they provide a 1 year warranty on the HBB following the reconditioning. Only thing they cannot do is repair issues with the ABS solenoid section of the HBB.

Anyhow. A great result for your efforts.

[Shano592]

Great write-up!

Who was the rewinder? Excellent, economical service should have the word spread!

[youcanlaugh]

Great write-up!

Who was the rewinder? Excellent, economical service should have the word spread!

Thanks.

The guy who refurbished the Pump Motor for me in Western Australia was Mark from T.K.F. Auto Rewind & Wholesale 08 9249 4261. A really helpful guy.

[ruh2001]

Sorry if I ask this question here.

Are the pump motor from an NP will fit in my NM?

[youcanlaugh]

Sorry if I ask this question here.

Are the pump motor from an NP will fit in my NM?

Hi Ruh2001, Yep, it looks like it should fit all Mk3's. 2002 onwards. I think they changed the accumulator. It used to be a round black one but they replaced them with a brass coloured more cylindrical one. They had a recall on 2003 (I think) models to do that.

[youcanlaugh]

You can purchase just the motor assembly after all

So Hungie pointed out to me that his dealer replaced just the motor assembley, which my dealer (and lots of other dealers from what I have seen) have said you can't do (saying they only sold the entire unit).

It is Part Number MN102843 which translates to Mitsubishi part 54242 on their diagrams (see below) and is the lower section of the HBB including the motor. Interestingly, the same part appears to be used on Chryslers. I just got a quote from the dealer here in WA for $917.40 (part only).

[ruh2001]

Hi Ruh2001, Yep, it looks like it should fit all Mk3's. 2002 onwards. I think they changed the accumulator. It used to be a round black one but they replaced them with a brass coloured more cylindrical one. They had a recall on 2003 (I think) models to do that.

Thank you...
My friend gave me a complete HBB from an NP and will check the motor/bushes.

[youcanlaugh]

Thank you...
My friend gave me a complete HBB from an NP and will check the motor/bushes.

Gee, good friend to have. :-) Definitely worth checking the brushes & bearings. Mine were all shot and the entire motor body was full of carbon dust.

I've had mine back together for a couple of weeks now and it is working great. I've definitely got better breaking now although I reckon that may be down to the replacements pads I put in all round while I was doing it.

I was expecting the buzzer and warning lights to go off while driving it for the first week (even though I was confident I had fixed it). I think the fear of losing my brakes again were greater than my confidence in a good repair.

[ruh2001]

I had removed and opened the motor. Acummutator is still okat will change the brushes if these motor turns okay I keep it for future use

[my.paj]

Just thought I would add this other thread aswell.

http://www2.pajeroclub.com.au/forum/showthread.php?t=47607

[Gok]

Thanks mate you answered all my questions on how this unit works and how to repair it, if needed. Thanks again for you time and effort in your great post.

[wrexy]

Mine failed while in Peron NP, 1000 km from Perth last year. Long trip home towing camper with no brakes. New price varied from $2600 in Geraldton to $3100 from Southside Mitsi. Got a 2nd hand unit from Mitsubi parts in Malaga for $500. First one was faulty so cost me more labour to change over. I pulled the old unit apart to have a look inside. These are incredibly complex with a rabbit warren of ports and galleries for abs & Tc. Big and bulky, gotta be $5 in scrap aluminium.

[amnash]

How many kms were on this when your brakes failed?

[Pilks]

Time for me to do this...

So after months of thinking about this I have finally made the decision to have the motor rewound. Any of you that have followed some of my older threads will know that I had a mystery chirp noise coming when I brake. At first this appeared to be tied to the outside temperature. Anyway skip forward a few months and this is now a regular noise throughout the day and has been worrying me that at any point the alarm would go off and my brakes would disappear.
I was fairly convinced that the noise is now the worn bushes rubbing against the motor housing. I had spoken with Mark from TKF and he pretty much confirmed this.
I wasn't game to pull the thing apart (lack of time and confidence). So went and saw my friendly local mechanic. He got this off in a couple of hours this morning and I have the motor booked in for tomorrow with TKF.

One slight problem I have to deal with now is the terminal where the harness from the motor joins the HBB. There is a fair bit of corrossion and my mechanic wouldn't touch it as he doesnt want to be liable for breaking it.
I've flooded it with WD40 and will let it soak for a bit and give it some TLC later. Fingers crossed.