MITSUBISHI ENDEAVOR 2004 Service Repair Manual

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

5. If the run-out cannot be corrected by changing the phase of the brake disc,
replace the brake disc or grind it with the on-the-car type brake lathe ("MAD,
DL-8700PF" or equivalent). MASTER CYLINDER FUNCTION CHECK 1. Remove the reservoir cap.
2. While watching the open reservoir from a distance of 50 cm (20 inches), have
an assistant depress the brake pedal. If there was a stream of brake fluid rising
from the reservoir, proceed to Step 3. If there was no stream of brake fluid
rising from the reservoir, repair or replace the master cylinder.
3. While watching the open reservoir from a distance of 50 cm (20 inches), have
the assistant release the brake pedal. If there was a small amount of air bubbles
rising through the brake fluid, master cylinder function is normal. If there were
no bubbles rising through the brake fluid, repair or replace the master cylinder. BRAKE PEDAL REMOVAL AND INSTALLATION
Fig. 42: Identifying M12 Flat Washer

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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. 43: Removing/Installing Brake Pedal Component

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INSPECTION STOPLIGHT SWITCH CHECK 1. Connect an ohmmeter between the sto
plight switch connector terminals.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 44: Connecting Ohmmeter Between Stoplight Switch Connector Terminals

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. There should be no continuity between the terminals when the plunger is
pushed in as shown. There should be continuity when it is released.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 45: Stoplight Switch Specification

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y of MITSUBISHI MOTOR SALES OF AMERICA
.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTE
R
REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 46: Removing/Installing Master Cylinder Assembly And Brake Booster Component

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tool:
MB991568: Push Rod Adjusting Socket
INSTALLATION SERVICE POINTS >>A<< BRAKE BOOSTER VACUUM HOSE CONNECTION Insert vacuum hose with its paint mark facing upward.
Fig. 47: Inserting Vacuum Hose

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>>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

1. Use the vacuum pump to measure dimension "A" applying a negative pressure
of 66.7 kPa (19.7 inHg) to the brake booster.
Standard value (A): 10.28 - 10.52 mm (0.405 - 0.414 inch)
NOTE: When a negative pressure of 66.7 kPa (19.7 inHg) is not
applied to the brake booster, the push rod protrusion
amount (A) should be 8.78 - 9.02 mm (0.346 - 0.355
inch).

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 48: Using Vacuum Pump To Measuring Dimension "A"

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. If the protrusion amount is not within the standard value range, adjust the push
rod length by turning the push rod. Use special tool MB991568 to turn the push
rod while holdin
g the rod s
pline with an
gle-nose
pliers.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor