MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 58: Blowing Compressed Air From Connecting Portion Of The Brake Hose

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2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

<< B>> PISTON SEAL REMOVAL 1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol brake fluid DOT 3 or
DOT 4.
Fig. 59: Cleaning Piston Surface And Inner Cylinder With Alcohol Brake
Fluid

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CAUTION: Do not use a flat-tipped screwdriver or similar tool to
remove the piston seal. These may damage the inner
side of the cylinder.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

DISASSEMBLY AND ASSEMBLY < REAR>Fig. 60: Exploded View Of Brake Disc (Rear)

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

Fig. 61: Identifying Lubrication Points

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DISASSEMBLY SERVICE POINTS << A>> PISTON BOOT/CALIPER PISTON REMOVAL
CAUTION: When disassembling the disc brakes, disassemble
both sides (left and right) as a set.
CAUTION: Blow air little by little to remove the piston. The

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air
through the brake hose connection hole to remove the piston boot and piston.
Fig. 62: Removing Piston Boot/Caliper Piston

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<< B>> PISTON SEAL REMOVAL
piston will pop out if a force of air is applied
suddenly.
CAUTION: Do not use a flat-tipped screwdriver or similar tool to

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

1. Remove the piston seal with your finger tip.
2. Clean piston surface and inner cylinder with alcohol or brake fluid DOT 3 or
DOT 4.
Fig. 63: Removing Piston Seal

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ASSEMBLY SERVICE POINT >>A<< REAR BRAKE PIN INSTALLATION
remove piston seal. These may damage the inner
side of the cylinder.

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Attach a guide pin (with "g" on the bolt head) at the bleeder nipple side of the
caliper body and a lock pin (with "l" on the bolt head) at the opposite side. INSPECTION
Check the cylinder for wear, damage or rust. Check the piston surface for wear, damage or rust. Check the caliper body or sleeve for wear. Check the pad for damage or adhesion of grease, check the backing metal for
damage.
PAD WEAR CHECK 1. Measure thickness at the thinnest and most worn area of the pad.
Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
WARNING:
Always replace both brake pads on each wheel
as a set (both front wheels or both rear wheels).
Failure to do so will result in uneven braking,
which may cause unreliable brake operation. If there is significant difference in the thickness
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. 64: Checking Pad Wear

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2. Replace the pad assembly if pad thickness is less than the limit value.
SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS
2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 65: Fastener Tightening Specifications

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GENERAL SPECIFICATIONS Fig. 66: General Specifications (1 Of 2)

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2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 67: General Specifications (2 Of 2)

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SERVICE SPECIFICATIONS Fig. 68: Service Specifications

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2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor