MITSUBISHI ENDEAVOR 2004 Service Repair Manual

The master cylinder used has no check valve, so if bleeding is carried out by the
following procedure, bleeding of air from the brake pipeline will become easier.
(When brake fluid is not contained in the master cylinder).
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a finger.
Fig. 26: Identifying Master Cylinder Outlet

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2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 - 4 three or four times to fill the inside of the master cylinder
with brake fluid. BRAKE LINE BLEEDING Start the en
gine and bleed the air in the se
quence shown in the fi
gure.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 27: Identifying Brake Line Bleeding Sequence

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BRAKE FLUID LEVEL SENSOR CHECK
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

The brake fluid level sensor is in good condition if there is no continuity when the
float surface is above "MIN" and if there is continuity when the float surface is
below "MIN".
Fig. 28: Checking Brake Fluid Level Sensor

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DISC BRAKE PAD CHECK AND REPLACEMENT NOTE: The brake pads (LH wheel) have indicators that contact the
brake disc when the brake pad thickness becomes 2 mm
(0.08 inch), and emit a squealing sound to warn the driver.
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

1. Check the brake pad thickness through the caliper body check port.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
Fig. 29: Checking DISC Brake Pad And Replacement

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CAUTION:
Whenever a pad must be replaced, replace both
LH and RH wheel pads as a set to prevent the
vehicle from pulling to one side when braking. If there is a significant difference in the
thicknesses of the pads on the left and right
sides, check the sliding condition of the piston
and slide pins.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 30: Checking Brake Pad Thickness (Front)

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2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 31: Checking Brake Pad Thickness (Rear)

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2. Remove the lock pin bolt. Pivot the caliper assembly and hold it with wires.
CAUTION: Do not wipe off the special grease that is on the
lock pin or allow it to contaminate the lock pin.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 32: Removing Lock Pin Bolt (Front)

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2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 33: Removing Lock Pin Bolt (Rear)

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3. Remove the following parts from caliper support.
1. Pad assembly
2. Pad and wear indicator assembly or Pad assembly
3. Shim
4. Clip
4. In order to measure the brake drag force after pad installation, measure the
rotary-sliding resistance of the hub with the pads removed (Refer to
INSPECTION
).
5. Install the pads and caliper assembly, and then check the brake drag force
(Refer to INSPECTION
).

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 34: Removing Caliper Support Component

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISC BRAKE ROTOR CHECK
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor