MITSUBISHI ENDEAVOR 2004 Service Repair Manual

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

installation easier.
3. The master cylinder reservoir tank cap has been colored white to make
identification easier.
4. The ABS-ECU and hydraulic unit have been integrated to make them more
compact and light weight.
CONSTRUCTION DIAGRAM < VEHICLE WITH ABS>
Fig. 1: Identifying Vehicle With ABS Brake

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
< VEHICLE WITHOUT ABS>

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 2: Identifying Vehicle Without ABS Brake

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
BASIC BRAKE SYSTEM DIAGNOSIS INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster
and disc brakes. Malfunctions such as insufficient braking power or the generation
of noise may occur due to wear, damage or incorrect adjustment of these
components. BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you
will be sure that you have exhausted most of the possible ways to find a basic brake
system fault.
1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the symptom chart.
4. Verif
y malfunction is eliminated.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

SYMPTOM CHART Fig. 3: Symptom Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: VEHICLE PULLS TO ONE SIDE WHEN BRAKES ARE APPLIED DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad contact surface 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.
Then go to Step 5 .
NO: Go to Step 2.
STEP 2. Check disc brake pistons for smooth operation.
1. With engine not running, depress the brake pedal rapidly several times to
deplete booster vacuum reserves.
2. Test each disc brake assembly one at a time.
a. Remove the lower caliper bolt, then remove caliper from mount.
b. Have an assistant slowly depress the brake pedal. Confirm piston(s)
extend slowl
y and smoothl
y with no
jum
piness. Re
peat for each disc

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

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

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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
.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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