MITSUBISHI ENDEAVOR 2004 Service Repair Manual

STEP 3. Check for looseness of the caliper installation bolt.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

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

STEP 5. 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
.
SPECIAL TOOLS Fig. 13: Identifying Special Tools

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ON-VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value: 181.2 - 184.2 mm (7.13 - 7.25 inches) [From the surface of
dash panel to the face of pedal pad]
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 14: Measuring Brake Pedal Height

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

3. If the brake pedal height is not within the standard value, follow the procedure
below.
1. Disconnect the stoplight switch connector.
2. Remove the brake booster (Refer to MASTER CYLINDER
ASSEMBLY AND BRAKE BOOSTER
).
3. Adjust the brake pedal height by turning the clevis.
4. Install the brake booster (Refer to MASTER CYLINDER ASSEMBLY
AND BRAKE BOOSTER
).
5. Measure the brake pedal height, and ensure that the measured value is
within the specified value. When it is out of the specified value, repeat
Ste
ps 3 -6 .
NOTE: With the master cylinder and brake pipe connected,
remove the brake booster only.
NOTE: When the clevis is turned 180 degrees, the pedal
height is changed approximately 2.2 mm (0.09 in).

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 15: Adjusting Brake Pedal Height By Turning Clevis

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Screw in the stop light switch until its thread contacts the stopper, and fix
the stop light switch by turning it approximately one quarter of a turn
clockwise.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 16: Checking Clearance Between Stop Light Switch And Stopper

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Check that the clearance between the stop light switch and the stopper is
as shown.
8. Connect the connector at the stop light switch.
4. Check the key interlock and shift lock mechanisms. (Refer to KEY
INTERLOCK AND SHIFT LOCK MECHANISM CHECK
).
5. Return the carpet, etc. to its original position.
BRAKE PEDAL FREE PLAY
CAUTION: Check that the stop light does not illuminate
when the brake pedal is not depressed.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

1. Turn the ignition switch to the "LOCK" (OFF) position, depress the brake
pedal two or three times. After eliminating the vacuum in the brake booster,
press the pedal down by hand, and confirm that the amount of movement
before resistance is met (free play) is within the standard value range.
Standard value: 3 - 8 mm (0.12 - 0.31 inch)
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor