MITSUBISHI ENDEAVOR 2004 Service Repair Manual

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. 36: Measuring Disc Thickness

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
NOTE: Thickness variation (at least 8 positions) should not be
more than 0.015 mm (0.0006 inch).

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

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

Fig. 38: Installing Digital Gauge

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. If the brake disc run-out exceeds the limit, correct it as follows:
1. Chalk phase marks on the wheel stud and the brake disc, which run-out is
excessive as shown.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 39: Identifying Chalk Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Remove the brake disc. Then 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)

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 40: Measuring End Play Brake Disc (Front)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. If the end play exceeds the limit, replace the hub assembly.
4. If the end play does not exceed the limit, dephase the brake disc and
secure it. Then recheck the brake disc run-out.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 41: Measuring End Play Brake Disc (Rear)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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