oil MITSUBISHI ENDEAVOR 2004 Service Repair Manual

2004 TRANSMISSION
Automatic Transaxle Overhaul - Endeavor
GENERAL INFORMATION This automatic transaxle is made up of the following main parts.
The gear train is made up of 3 multi-plate clutches, 2 multi-plate brakes and 2
planetary gears made up of a sun gear, carrier, pinion gear and annulus gear.
The torque converter employs a 3 element, 1 step, 2 phase lock-up clutch.
The cases consist of a converter housing, transaxle case, rear cover and a valve
body cover.
Parts related to oil pressure regulation are the oil pump, which pressurizes the oil;
the regulator, which controls the pressure setting; the solenoid valves, which
changes the oil pressure with electrical signals; the pressure control valve, which
controls the oil pressure coming from the solenoid valve that effects each clutch and
brake; each kind of valve, which carry out the retention of the oil pressure through
the lines; and finally the valve body, which houses all the valves. SECTIONAL VIEW < F4A5A >
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor


2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Required Special Tools:
MB990607: Torque Wrench Socket MB990930: Installer Adapter MB990931: Installer Adapter MB990936: Installer Adapter MB990938: Handle MB991625: Special Socket (41) MB991632: Clearance Dummy Plate MD998323: Bearing Installer MD998333: Oil Pump Remover MD998338: Oil Pump Remover MD998412: Guide MD998913: Dial Gauge Extension MD998924: Spring Compressor Retainer
DISASSEMBLY
CAUTION:
Because the automatic transaxle is manufactured
from high-precision parts, care must be taken not
to scratch or damage these parts during
disassembly and assembly. The working area should be covered with a
rubber mat to keep it clean at all times. Do not wear any cloth gloves and do not use any
shop towels during disassembly. Use only nylon
cloth, paper towels or any other lint-free material. Parts which have been disassembled should all
be cleaned. Metal parts can be cleaned with
normal detergent, but they should be dried
completely using compressed air. Clutch discs, plastic thrust plates and rubber
parts should be cleaned with automatic

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

1. Remove the transfer and O-ring < W4A5A >
2. Use a dial gauge to measure the input shaft end play.
3. Remove the torque converter.
4. Remove each bracket.
5. Remove the dipstick.
6. Remove the eye bolt, gaskets and the oil cooler feed tube.
Fig. 13: Measuring Input Shaft End Play
transmission fluid (ATF). If the transaxle body has been damaged,
disassemble and clean the cooler system.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 22: Identifying Snap Ring From Connector

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
16. Remove the strainer and the second brake retainer oil seal.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 23: Identifying Strainer And Second Brake Retainer Oil Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
17. Remove each accumulator piston and spring

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 29: Removing Differential Bearing Outer Race From Transaxle Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
25. Remove the oil filter.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 30: Removing Oil Filter

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
26. Remove the oil pump mounting bolts (six pieces).
27. Install s
pecial tool MD998333 in hole "A".

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 31: Removing Oil Pump Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
28. Turn special tools MD998333 to remove the oil pump.
29. Remove the oil
pum
p gasket.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 32: Turning Special Tools MD998333 To Removing Oil Pump

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
30. Remove thrust washer number 1.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 62: Removing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ASSEMBLY
CAUTION:
Do not reuse the gasket, O-ring, oil seal. Always
replace with a new one when assembling. Do not use grease other than petroleum jelly
(Vaseline). Apply ATF to friction components, rotating parts,
and sliding parts before installation. Immerse a
new clutch disc or brake disc in ATF for at least
two hours before assembling them. When replacing a bushing, replace the assembly
which it belongs to.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor