MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 49: Using Special Tool Mb991568

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
MA
STER
CYLI
NDER

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

DISASSEMBLY AND ASSEMBLY Fig. 50: Disassembling And Assembling Master Cylinder

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DISASSEMBLY SERVICE POINT
<< A>> BRAKE MASTER CYLINDER UNION RETAINER DISASSEMBLY Remove the brake master c
ylinder union retainer while de
pressin
g the
piston.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 51: Disassembling Brake Master Cylinder Union Retainer

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INSPECTION
Check the inner surface of master cylinder body for rust or pitting. Check the primary and secondary pistons for rust, scoring, wear or damage.
DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 52: Removing/Installing Disc Brake Assembly

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INSTALLATION SERVICE POINT >>A<< BRAKE CALIPER ASSEMBLY INSTALLATION 1. In order to measure the brake drag force, measure the hub torque with the pads
removed by the following procedure. Use a spring scale to measure the hub
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

torque in the forward direction. Record hub torque with pads removed.
Fig. 53: Measuring Hub Torque Without Pads

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2. After re-installing the caliper support to the knuckle, install the pad clips and
the pads to the caliper support.
3. Clean the piston and insert into cylinder with special tool MB990520.
4. Be careful that the piston boot does not become caught, when lowering the
caliper assembly and installing the lock pin bolt.
5. Check the brake drag force as follows.
CAUTION: Do not let any oil, grease or other contamination
get onto the friction surfaces of the pads and
brake discs.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

1. Start the engine and hold the brake pedal down for 5 seconds. [Pedal
depression force: approximately 200 N (45 pound)]
2. Stop the engine.
3. Turn the brake disc forward 10 times.
4. Use a spring scale to measure the hub torque with pads installed in the
same direction as earlier.
5. Calculate the drag force of the disc brake [difference between hub torque
with pads installed and hub torque with pads removed].
Standard value: 68 N (15 pounds) or less
Fig. 54: Measuring Drag Force

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y of MITSUBISHI MOTOR SALES OF AMERICA
.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

6. If the brake drag force exceeds the standard value, disassemble and clean the
piston. Check for corrosion or worn piston seal, and check the sliding condition
of the lock pin and guide pin.
Fig. 55: Measuring Hub Torque With Pads

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INSPECTION BRAKE DISC CHECK
Disc wear (Refer to DISC BRAKE ROTOR CHECK
).
Disc run-out (Refer to DISC BRAKE ROTOR CHECK
).
DISASSEMBLY AND ASSEMBLY < FRONT>
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 56: Exploded View Of Brake Disc (Front)

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LUBRICATION POINTS
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 57: Identifying Lubrication Points

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DISASSEMBLY SERVICE POINTS << A>> CALIPER PISTON/PISTON BOOT REMOVAL
CAUTION: When disassembling the front disc brakes,
disassemble both sides (left and right wheels) as a
set.
CAUTION:
When removing the pistons, be sure to use the

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Blow compressed air slowly from the connecting portion of the brake hose to pull
out the
piston and the
piston boots.handle of a plastic hammer and adjust the height
of the two pistons while pumping in air slowly so
that the pistons protrude evenly. Do not remove one piston completely before
trying to remove the other piston, because it will
become impossible to remove the second piston. Blow air little by little to remove the piston. The
piston will pop out if a force of air is applied
suddenly.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor