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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
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and no contamination is found
.
Q: Is there a fault?
YES: Refill or replace with the specified brake fluid DOT 3 or DOT 4.
Bleed the brakes if necessary (Refer to PROPORTIONING VALVE
FUNCTION TEST < Vehicles without ABS>
). Then go to Step 7 .
NO: Go to Step 2.
STEP 2. Check for spongy (not firm brakes).
1. With engine not running, depress the brake pedal rapidly several times to
deplete booster vacuum reserve.
2. With the brake pedal fully released, depress the brake pedal slowly until it
stops.
3. With a measuring device (ruler, etc.) next to the brake pedal, depress the
pedal firmly and measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES: Bleed the brakes to remove air in the fluid (Refer to
PROPORTIONING VALVE FUNCTION TEST < Vehicles without
ABS>
). Then go to Step 7 .
NO: Go to Step 3.
STEP 3. Check the brake booster function.
Refer to BRAKE PEDAL FREE PLAY
.
Q: Is there a fault?
YES: Replace the brake booster. Then go to Step 7 .
NO: Go to Step 4.
STEP 4. Check for pinched or restricted brake tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES: Replace that complete section of brake tube or brake hose. Then go
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to Step 7 .
NO: Go to Step 5.
STEP 5. Check for oil, water, etc., on the pad contact surfaces of all
brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES: Replace the part and determine the source/cause of foreign material.
Recheck symptom. Then go to Step 7 .
NO: The procedure is complete. If condition persists for vehicles without
ABS, go to Step 6.
STEP 6. Check the proportioning valve operation. < Vehicles without
ABS>
Refer to PROPORTIONING VALVE FUNCTION TEST < Vehicles
without ABS>
.
Q: Is there a fault?
YES: Replace the proportioning valve. Then go to Step 7.
NO: Go to Step 7.
STEP 7. 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
appropriate SYMPTOM CHART
.
INSPECTION PROCEDURE 3: INCREASED PEDAL STROKE (REDUCED PEDAL-TO-FLOOR BOARD
CLEARANCE) DIAGNOSIS
STEP 1. Check for spongy (not firm) brakes.
1. With engine not running, depress the brake pedal rapidly several times to
de
plete booster vacuum reserve.
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2. With the brake pedal fully released, depress the brake pedal slowly until it
stops.
3. With a measuring device (ruler, etc.) next to the brake pedal, depress the
pedal firmly and measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES: Bleed the brakes to remove air in the fluid (Refer to
PROPORTIONING VALVE FUNCTION TEST < Vehicles without
ABS>
). Then go to Step 7 .
NO: Go to Step 2.
STEP 2. Check the pad for wear.
Refer to DISC BRAKE PAD CHECK AND REPLACEMENT
.
Q: Is the pad thickness outside of specifications?
YES: Replace the part. Then go to Step 7 .
NO: Go to Step 3.
STEP 3. Check the vacuum hose and check valve for damage.
Refer to CHECK VALVE OPERATION CHECK
.
Q: Is there a damage?
YES: Replace the part. Then go to Step 7 .
NO: Go to Step 4.
STEP 4. Check the master cylinder function.
Refer to MASTER CYLINDER FUNCTION CHECK
.
Q: Is there a fault?
YES: Repair it. Then go to Step 7 .
NO: Go to Step 5.
STEP 5. Check for brake fluid leaks
.
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Q: Is there a leak?
YES: Check the connection for looseness, corrosion, etc. Clean and repair
as necessary. If leaking in any tube or hose section, replace the complete
tube or hose. Then go to Step 7 .
NO: Go to Step 6.
STEP 6. Check the clearance (too much) between the push rod and
primary piston.
Refer to MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
.
Q: Is the clearance outside of specifications?
YES: Adjust the clearance. Then go to Step 7.
NO: Go to Step 7.
STEP 7. 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 4: BRAKE DRAG DIAGNOSIS
STEP 1. Check the parking brake operating lever return.
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Fig. 4: Checking Parking Brake Operating Lever Return
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the operation faulty?
YES: Repair it. Then go to Step 9 .
NO: Go to Step 2.
STEP 2. Check the brake shoe s
prin
gs for breaka
ge.
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor
Page 711 of 3870
Fig. 5: Checking Brake Shoe Springs For Breakage
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Are the brake shoe springs broken?
YES: Replace the spring. Then go to Step 9 .
NO: Go to Step 3.
STEP 3. Check the amount of grease at each sliding section.
Refer to PARKING BRAKE LINING AND DRUM .
Q: Is the grease amount low?
YES: Apply grease. Then go to Step 9 .
NO: Go to Step 4.
STEP 4. Check the parking brake pull amount.
Refer to PARKING BRAKE PEDAL STROKE CHECK AND
AD
JUS
TME
.
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2004 BRAKES Basic Brake System - Endeavor
Page 712 of 3870
Q: Is there a fault?
YES: Adjust it. Then go to Step 9 .
NO: Go to Step 5.
STEP 5. Check the clearance (too low) between the push rod and primary
piston.
Refer to MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
.
Q: Is there a fault?
YES: Adjust the clearance. Then go to Step 9 .
NO: Go to Step 6.
STEP 6. Check the master cylinder piston return spring for damage and
return port for clogging.
Refer to MASTER CYLINDER
.
Q: Is there a damage?
YES: Replace the part. Then go to Step 9 .
NO: Go to Step 7.
STEP 7. Check port for clogging.
Q: Is the port clogged?
YES: Repair it. Then go to Step 9 .
NO: Go to Step 8.
STEP 8. Check disc brake pistons for sticking.
Depress the brake pedal, then release. Confirm each wheel spins freely.
Q: Are all wheels stuck?
YES: Inspect that brake assembly. Then go to Step 9.
NO: Go to Ste
p 9.
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor