2004 MITSUBISHI ENDEAVOR service

YES: Replace the part. Then go to Step 10 .
NO: Go to Step 9.
STEP 9. Adjust the brake pedal or brake booster pushrod.
Refer to ON
-VEHICLE SERVICE
or MASTER CYLINDER ASSEMBLY
AND BRAKE BOOSTER
.
Q: Are the brake pedal and the brake booster pushrod adjusted correctly?
YES: Go to Step 10.
NO: Adjust the brake pedal or the brake booster pushrod. Then go to Step
10.
STEP 10. Recheck symptom.
Q: Is the symptom eliminated?
YES: The procedure is complete.
NO: Start over at Step 1 . If a new symptom surfaces, refer to the
SYMPTOM CHART .
INSPECTION PROCEDURE 8: GROANING, CLICKING OR RATTLING NOISE WHEN BRAKES ARE NOT
APPLIED DIAGNOSIS
STEP 1. Check whether foreign material has entered the wheel covers.
Q: Is there a foreign material?
YES: Remove it. Then go to Step 5 .
NO: Go to Step 2.
STEP 2. Check for looseness of the wheel nuts.
Q: Are the wheel nuts loose?
YES: Tighten to 98 +/- 10 N.m (73 +/- 7 ft-lb). Then go to Step 5 .
NO: Go to Ste
p 3.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

STEP 5. Recheck symptom.
Q: Is the symptom eliminated?
YES: The procedure is complete.
NO: Start over at Step 1 . If a new symptom surfaces, refer to the
SYMPTOM CHART
.
SPECIAL TOOLS Fig. 13: Identifying Special Tools

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ON-VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value: 181.2 - 184.2 mm (7.13 - 7.25 inches) [From the surface of
dash panel to the face of pedal pad]
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

Fig. 46: Removing/Installing Master Cylinder Assembly And Brake Booster Component

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tool:
MB991568: Push Rod Adjusting Socket
INSTALLATION SERVICE POINTS >>A<< BRAKE BOOSTER VACUUM HOSE CONNECTION Insert vacuum hose with its paint mark facing upward.
Fig. 47: Inserting Vacuum Hose

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

DISASSEMBLY AND ASSEMBLY Fig. 50: Disassembling And Assembling Master Cylinder

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISASSEMBLY SERVICE POINT
<< A>> BRAKE MASTER CYLINDER UNION RETAINER DISASSEMBLY Remove the brake master c
ylinder union retainer while de
pressin
g the
piston.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 52: Removing/Installing Disc Brake Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINT >>A<< BRAKE CALIPER ASSEMBLY INSTALLATION 1. In order to measure the brake drag force, measure the hub torque with the pads
removed by the following procedure. Use a spring scale to measure the hub
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 57: Identifying Lubrication Points

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISASSEMBLY SERVICE POINTS << A>> CALIPER PISTON/PISTON BOOT REMOVAL
CAUTION: When disassembling the front disc brakes,
disassemble both sides (left and right wheels) as a
set.
CAUTION:
When removing the pistons, be sure to use the

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 61: Identifying Lubrication Points

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISASSEMBLY SERVICE POINTS << A>> PISTON BOOT/CALIPER PISTON REMOVAL
CAUTION: When disassembling the disc brakes, disassemble
both sides (left and right) as a set.
CAUTION: Blow air little by little to remove the piston. The

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor