MITSUBISHI ENDEAVOR 2004 Service Repair Manual

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
.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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

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. 6: Checking Interference Between Dust Cover And Brake Disc

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is there a interference?
YES: Repair or replace the part. Then go to Step 6 .
NO: Go to Step 4.
STEP 4. Check the brake drums or discs for cracks.
Q: Are there cracks?
YES: Repair or replace the part. Then go to Step 6 .
NO: Go to Step 5.
STEP 5. Check for bent backing plate(s).

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 7: Removing Bent Backing Plate(S)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is (Are) the backing plate(s) bent?
YES: Repair or replace the part. Then go to Step 6.
NO: Go to Step 6.
STEP 6. 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 6: SQUEALING, GROANING OR CHATTERING NOISE WHEN BRAKES ARE
APPLIED
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

DIAGNOSI
S
STEP 1. Check the brake disc and pads for wear or cutting.
Q: Is there a wear or cutting?
YES: Repair or replace the part. Then go to Step 4 .
NO: Go to Step 2.
STEP 2. Check the calipers for rust.
Q: Is there a rust?
YES: Remove the rust. Then go to Step 4 .
NO: Go to Step 3.
STEP 3. 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 4.
NO: Adjust the brake pedal or the brake booster pushrod. Then go to Step
4.
STEP 4. 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 7: SQUEALING NOISE WHEN BRAKES ARE NOT APPLIED DIAGNOSIS
STEP 1. Check whether the backing plate is bent or loose and interfering
with the drum
.

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

NO: Go to Step 7.
STEP 7. 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.
Limit: 0.05 mm (0.002 inch)
Fig. 8: Measuring Wheel Bearings For End Play (Front)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

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