2004 MITSUBISHI ENDEAVOR Rear end

A. Wrap tape around the spline part of the shaft, then install BJ boot and DOJ
boot. Fill the inside of the BJ and BJ boot with specified grease. Tighten the
boot band.
B. Install the DOJ cage to the axle shaft and put it aside to BJ assembly side.
Align the mating mark to DOJ inner race with that of the shaft. See Fig. 8
. Tap
the inner race with even force to press-fit into the bump of the shaft with Brass
Bar (MB990939).
C. Fill the inside of the DOJ outer race and DOJ boot with the specified grease.
D. Position the DOJ outer race so that the distance between the boot bands as
shown. See Fig. 9
. Remove part of the DOJ boot from the DOJ outer race to
release the air pressure inside the boot.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease.

2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Rear - Endeavor

Fig. 8: Installing Double Offset Joint (DOJ) Cage & Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fig. 9: Installing Double Offset Joint (DOJ) Boot Bands (Small & Large)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
TORQUE SPECIFICATIONS For tor
que s
pecifications, see Fi
g. 2
.

2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Rear - 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

STEP 9. 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 5: SCRAPING OR GRINDING NOISE WHEN BRAKES ARE APPLIED DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for metal-to-metal
condition.
Q: Is the metal-to-metal contact evident?
YES: Repair or replace the components. Then go to Step 6 .
NO: Go to Step 2.
STEP 2. Check for interference between the caliper and wheel.
Q: Is there a interference?
YES: Repair or replace the part. Then go to Step 6 .
NO: Go to Step 3.
STEP 3. Check for interference between the dust cover and brake disc.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 9: Measuring Wheel Bearings For End Play (Rear)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Does the measured end play exceed the limit?
YES: Replace the faulty hub assembly. Then go to Step 10 .
NO: Go to Step 8.
STEP 8. Check whether the brake booster or master cylinder return is
insufficient.
Q: Is the brake booster or master c
ylinder return insufficient?

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 10: Checking Looseness Of Caliper Installation Bol
t
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the caliper installation bolt loose?
YES: Tighten to 100 +/- 10 N.m (74 +/- 7 ft-lb) for the front caliper.
Tighten to 60 +/- 5 N.m (45 +/- 3 ft-lb) for the rear caliper. Then go to
Step 5 .
NO: Go to Step 4.
STEP 4. Check the wheel bearings for end play.
1. Remove the brake discs.
2. Place a dial gauge as shown, and measure the end play while moving the
hub in the axial direction.
Fig. 11: Measuring Wheel Bearings For End Play (Front)

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
Fig. 12: Measuring Wheel Bearings For End Play (Rear)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Limit: 0.05 mm (0.002 inch)
Q: Does the measured end play exceed the limit?
YES: Replace the faulty hub assembly. Then go to Step 5.
NO: Go to Ste
p 5.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor