MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Step 9 .
NO: Go to Step 2.
STEP 2. Check the tooth contact (engagement) of the drive gear and drive
pinion (Refer to DISASSEMBLY
).
Q: Is the tooth contact (engagement) of the drive gear and drive pinion
correct?
YES: Go to Step 3.
NO: Adjust or replace the part. Then go to Step 9 .
STEP 3. Check the side bearing for looseness, wear or damage.
Q: Is the side bearing loose, worn or damaged?
YES: Adjust or replace the part. Then go to Step 9 .
NO: Go to Step 4.
STEP 4. Check the drive pinion bearing for wear or damage.
Q: Is the drive pinion bearing worn or damaged?
YES: Adjust or replace the part. Then go to Step 9 .
NO: Go to Step 5.
STEP 5. Check the drive gear and drive pinion for wear.
Q: Is the drive gear or drive pinion worn?
YES: Replace the part. Then go to Step 9 .
NO: Go to Step 6.
STEP 6. Check the side gear spacer or pinion shaft for wear.
Q: Is the side gear spacer or pinion shaft worn?
YES: Replace the part. Then go to Step 9 .
NO: Go to Step 7.
STEP 7. Check the drive gear and differential case for wear or damage.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Q: Is the drive gear or differential case strained or damaged?
YES: Replace the part. Then go to Step 9 .
NO: Go to Step 8.
STEP 8. Check for foreign material.
Q: Is any foreign material found?
YES: Remove the foreign material and then inspect for damage. If
necessary, replace the part. Then go to Step 9.
NO: Go to Step 9.
STEP 9. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 3: GEAR NOISE WHILE DRIVING {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler
plug and check the
gear oil level.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 5: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C
(-10°F): SAE 90, 85W-90, 80W-90, Fro
m-34 to-23°C
(-30

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

to-10°F): SAE 80W, 80W-90, Below-34°C (-30°F): SAE 75W. Then go to
Step 6 .
NO: Go to Step 2.
STEP 2. Check the gear engagement.
Q: Is the gear engagement in good condition?
YES: Go to Step 3.
NO: Adjust or replace the part. Then go to Step 6 .
STEP 3. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES: Go to Step 4.
NO: Adjust the turning torque. Then go to Step 6 .
STEP 4. Check the gear for damage.
Q: Is the gear damaged?
YES: Replace the gear. Then go to >Step 6.
NO: Go to Step 5.
STEP 5. Check for foreign material.
Q: Is foreign material found?
YES: Remove the foreign material and then inspect for damage. If
necessary, replace the part. Then go to Step 6.
NO: Go to Step 6.
STEP 6. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 4: GEAR NOISE WHILE COASTING {{DIFFERENTIAL}}
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

DIAGNOSI
S
STEP 1. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES: Go to Step 2.
NO: Adjust the turning torque. Then go to Step 3 .
STEP 2. Check the gear for damage.
Q: Is the gear damaged?
YES: Replace the gear. Then go to Step 3.
NO: Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 5: BEARING NOISE WHILE DRIVING OR COASTING {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the drive pinion rear bearing for cracks or damage.
Q: Is the drive pinion rear bearing cracked or damaged?
YES: Replace the part. Then go to Step 2.
NO: Go to Step 2.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Ste
p 1.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

INSPECTION PROCEDURE 6: NOISE WHILE TURNING {{DIFFERENTIAL}}DIAGNOSIS
STEP 1. Check the side bearing for wear or damage.
Q: Is the side bearing worn or damaged?
YES: Replace the part. Then go to Step 3 .
NO: Go to step 2.
STEP 2. Check the side gear, pinion gear or pinion shaft for damage.
Q: Is the side gear, pinion gear or pinion shaft damaged?
YES: Replace the part. Then go to Step 3.
NO: Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 7: HEAT {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler
plug and check the
gear oil level.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 6: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C
(-10°F
): SAE 90, 85W-90, 80W-90, Fro
m-34 to-23°C
(-30

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

to-10°F): SAE 80W, 80W-90, Below-34°C (-30°F): SAE 75W. Then go to
Step 3 .
NO: Go to Step 2.
STEP 2. Check for excessive gear backlash (Refer to DISASSEMBLY
).
Q: Is the gear backlash correct?
YES: Go to Step 3.
NO: Adjust the backlash. Then go to step 3.
STEP 3. Retest the system.
Q: Is the heat eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 8: OIL LEAKAGE {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the cover installation.
Q: Is the cover installed correctly?
YES: Go to Step 2.
NO: Repair. Then go to Step 4 .
STEP 2. Check the oil seal for wear or damage.
Q: Is the oil seal worn or damaged?
YES: Replace the seal. Then go to Step 4 .
NO: Go to Step 3.
STEP 3. Check the oil level.
Remove the filler
plug and check the
gear oil level.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 7: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Refill Hypoid gear oil API classification GL-5 or higher; Above-23°
C (-10°F): SAE 90, 85W-90, 80W-90, From-34 to-23°C (-30 to-10°F):
SAE 80W, 80W-90, Below-34°C
(-30°F
): SAE 75W. Then
go to Ste
p 4.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

NO: Go to Step 4.
STEP 4. Retest the system.
Q: Is there oil leakage?
YES: Start over at Step 1.
NO: The procedure is complete.
SPECIAL TOOLS
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor