2004 MITSUBISHI ENDEAVOR brake rotor

with a new one if a problem is found.
TOOTHED ABS ROTOR CHECK Check whether the ABS rotor teeth are broken or deformed. Replace the BJ
assembly of the drive shaft, or the rear hub assembly, respectively, if the teeth are
damaged or deformed.
Fig. 163: Locating Tooth ABS Rotor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
G-SENSOR REMOVAL AND INSTALLATION NOTE: When checking for cable damage, remove the cable clamp
part from the body and then gently bend and pull the cable
near the clamp.
CAUTION: Do not drop or apply a shock on the G-sensor.

2004 Mitsubishi Endeavor LS
2004 BRAKES Anti-Lock Braking System (ABS) - Endeavor

2004 BRAKES
Basic Brake System - Endeavor
GENERAL DESCRIPTION The brake system has been designed to give greater reliability and durability and to
provide excellent braking performance. FEATURES IMPROVED BRAKING PERFORMANCE 1. A 9+10 inch tandem brake booster has been adopted to provide sufficient
braking force in sudden braking range.
2. Front ventilated disc brakes have been adopted to provide stabled braking force
and improved braking feel.
3. Rear solid disc brakes have been adopted. IMPROVED STABILITY 1. A 4-wheel anti-lock braking system (4ABS) has been adopted to prevent
slipping caused by the vehicle wheels locking up, in order to maintain a stable
vehicle posture and steering performance.
2. An electronic brake-force distribution (EBD) makes it possible to maintain the
maximum amount of braking force even when the vehicle's load is unevenly
distributed. < Vehicles with ABS>
3. A rear wheel early lock-prevention proportioning valve has been adopted. <
Vehicles without ABS>
4. Front- and rear-wheel X-type brake line layout has been adopted.
5. Ventilated discs have been adopted for front brakes in order to improve anti-
fading performance. IMPROVED SERVICEABILITY 1. A diagnosis function has been adopted for the ABS system in order to make
inspection easier.
2. An outer disc separated hub and rotor has been adopted to make removal and
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor


2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

brake assembly.
Q: Do (does) the piston(s) move correctly?
YES: Go to Step 3.
NO: Disassemble and inspect the brake assembly (Front: refer to
DISASSEMBLY AND ASSEMBLY < FRONT>
, Rear: refer to
DISASSEMBLY AND ASSEMBLY < REAR> ). Then go to Step 5 .
STEP 3. Check brake disc(s) for run out.
Refer to DISC BRAKE ROTOR CHECK
.
Q: Is runout outside of specifications?
YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5 .
NO: Go to Step 4.
STEP 4. Check brake discs for correct thickness.
Refer to DISC BRAKE ROTOR CHECK .
Q: Is the thickness outside of specifications?
YES: Repair or replace the brake disc(s) as necessary. Then go to Step 5.
NO: Carry out the brake line bleeding. Then go to Step 5.
STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES: The procedure is complete.
NO: Start over at Step 1 . If a new symptom appears, refer to the
appropriate SYMPTOM CHART
.
INSPECTION PROCEDURE 2: INSUFFICIENT BRAKING POWER DIAGNOSIS
STEP 1. Check that the specified brake fluid is used, its level is correct,

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Q: Is there a fault?
YES: Replace the part. Then go to Step 10 .
NO: Go to Step 2.
STEP 2. Check whether the drum is damaged due to interference with the
backing plate or shoe.
Q: Is there a damage?
YES: Replace the part. Then go to Step 10 .
NO: Go to Step 3.
STEP 3. Check the brake drum for wear and the shoe spring for damage.
Q: Is there a wear or damage?
YES: Replace the part. Then go to Step 10 .
NO: Go to Step 4.
STEP 4. Check the brake discs for rust.
Q: Are the brake discs rusted?
YES: Remove the rust by using sand paper. If still rusted, turn the rotors
with an on-the-car brake lathe. Then go to Step 10 .
NO: Go to Step 5.
STEP 5. Check the brake pads for correct installation.
Q: Are the pads installed incorrectly?
YES: Repair the pads. Then go to Step 10 .
NO: Go to Step 6.
STEP 6. Check the calipers for correct installation.
Q: Are the calipers installed incorrectly?
YES: Re
pair the cali
pers. Then
go to Ste
p 10 .

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 34: Removing Caliper Support Component

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISC BRAKE ROTOR CHECK
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Before turning the brake disc, the following conditions should be checked.
Fig. 35: Disc Brake Rotor Inspection Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
BRAKE DISC THICKNESS CHECK 1. Using a micrometer, measure disc thickness at eight positions, approximately
45 degrees apart and 10 mm (0.4 inch) in from the outer edge of the disc.
FRONT BRAKE DISC
Standard value: 26.0 mm (1.02 inches)
Minimum limit: 24.4 mm (0.96 inch)
REAR BRAKE DISC
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 8.4 mm (0.33 inch)
CAUTION: Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

CAUTION:
After a new brake disc is installed, alwa
ys grin
brake disc with on-the-car t
ype brake lathe. If
t
is not carried out, the brake disc run-out exce
e
specified value, resulting in judder. When the on-the-car t
ype lathe is used, first i
n
flat washer on the stud bolt in the brake disc
s
accordin
g to the fi
gure, and then install the a
d
the adapter is installed with M12 flat washer n
o
the brake disc rotor ma
y be deformed, resulti
n
inaccurate grinding.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

2. If the disc thickness is less than the limits, replace it with a new one. If
thickness variation exceeds the specification, turn rotor with an on-the-car type
brake lathe ("Accuturn-8750" or equivalent). If the calculated final thickness
after turning the rotor is less than the standard value, replace the disc. BRAKE DISC RUN-OUT CHECK AND CORRECTION 1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm (0.2 inch) from the outer
circumference of the brake disc, and measure the run-out of the disc.
Limit:
< Front brake disc>: 0.03 mm (0.0012 inch)
< Rear brake disc>: 0.08 mm (0.0031 inch)
Fig. 37: Identifying M12 Flat Washer

Courtes
y of MITSUBISHI MOTOR SALES OF
A
Grind the brake disc with all wheel nuts dia
gon
equall
y tightened to the specified torque 100
N
lb). When all numbers of wheel nuts are not u
s
the ti
ghtenin
g torque is excessive or not equa
brake disc rotor or drum ma
y be deformed, re
s
judder.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor