MITSUBISHI ENDEAVOR 2004 Service Repair Manual

tighten the strut nut.
Fig. 19: Compressing Spring

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4. Ensure that the arrows on the strut bracket center and the strut insulator are as
shown in illustration.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 20: Aligning Strut Insulator

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5. Using special tool MB991681, a hexagon wrench and a pipe, tighten the strut
nut to 65 +
/- 5 N.m
(48 +
/-4 f
t-lb
).
CAUTION: Do not use an impact wrench to tighten the strut
nut, otherwise the strut nut will be damaged.
Vibration of the impact wrench will cause the
valve inside the strut to dropout.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 21: Tightening Strut Nut

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INSPECTION
Check the strut bearing for wear or rust. Check the rubber parts for damage or deterioration. Check the coil spring for deformation, deterioration or damage. Check the front suspension strut for deformation.
LOWER ARM REMOVAL AND INSTALLATION
CAUTION: *: Indicates parts which should be temporarily
tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 22: Removing & Installing Lower Arm

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INSPECTION
Check the bushing for wear and deterioration. Check the lower arm assembly for bend or breakage. Check all bolts for condition and straightness.
LOWER ARM BALL JOINT BREAKAWAY TORQUE CHECK Required Special Tool:
MB991006: Preload Socket

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

1. After shaking the ball joint stud several times, use special tool MB991006 to
measure the breakaway torque of the ball joint.
Fig. 23: Measuring Ball Joint Breakaway Torque

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Standard value: 2.5 - 6.1 N.m (22 - 54 in-lb)
2. If the measured value is not within the standard value, or if the ball joint is
difficult to turn or does not turn smoothly, replace the lower arm assembly.
LOWER ARM BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger.
2. If the dust cover is cracked or damaged, replace the lower arm. BALL JOINT DUST COVER REPLACEMENT
NOTE: Cracks or damage to the dust cover may cause damage
to the ball joint. When it is damaged during service
work, replace the dust cover.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Required Special Tool
:
MB990800: Ball Joint Remover and Installer
If the dust cover is damaged accidentally during service work, replace the dust
cover as follows:
1. Remove the dust cover.
2. Apply the multipurpose grease SAE J310, NLGI No. 2 or equivalent to the lip
and the inside of a new dust cover.
Grease amount for the inside the dust cover (reference): 13 +/- 0.5 g (0.45
+/- 0.02 oz.)
3. Using special tool MB990800, drive in the dust cover until it is fully seated.
Fig. 24: Installing Dust Cover

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2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

4. Position the dust cover as shown in the illustration. Make sure that there is no
abnormal bulge or pressure applied on the dust cover.
Fig. 25: Positioning Dust Cover

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5. Check the dust cover for cracks or damage by pushing it with your finger.
LOWER ARM BUSHING (REAR) REPLACEMENT Required Special Tools:
MB991963: Suspension Bushing Arbor MB990889: Rear Suspension Bushing Ring MB990890: Rear Suspension Bushing Base
Replace the lower arm bushin
g as follows:

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 26: Identifying Lower Arm Bushing

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1. Use special tools MB991963 and MB990890 to drive out the lower arm
bushin
g.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 27: Removing Lower Arm Bushing

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2. Position the lower arm bushing so that its projections are as shown, and then
use special tools MB991963, MB990889 and MB990890 to press in the lower
arm bushing.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 28: Positioning Lower Arm Bushing

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3. Press the lower arm bushing until its outer tube is flush with the lower arm
assembly surface while checking that the press-in pressure is at the standard
value. If the press-in pressure is lower than the standard value, replace the
lower arm assembly.
Standard value: 9.8 kN (2,205 pounds) or more
CAUTION: When pressing in the lower arm bushing, take
care not to transform the lower arm.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor