MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 8: Identifying Special Tools (1 Of 4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig. 9: Identifying Special Tools (2 Of 4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig. 10: Identifying Special Tools (3 Of 4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig. 11: Identifying Special Tools (4 Of 4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ON-VEHICLE SERVICE REAR AXLE TOTAL BACKLASH CHECK 1. Park the vehicle on a flat, level surface.
2. Place the selector lever to the neutral position. Apply the parking brake and
jack up the vehicle.
3. Turn the propeller shaft clockwise as far as it will go. Make the mating marks
on the dust cover of the com
panion flan
ge and on the differential carrier.

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

Fig. 12: Making Mating Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Turn the propeller shaft counterclockwise as far as it will go, and measure the
amount of distance between the mating marks.
Limit: 5 mm (0.2 inch)

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

Fig. 13: Measuring Distance Between Mating Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. If the backlash exceeds the limit value, remove the differential carrier assembly
and check the following.
Final drive gear backlash (Refer to DISASSEMBLY
).
Differential gear backlash (Refer to DISASSEMBLY
).
GEAR OIL LEVEL CHECK 1. Remove the filler plug.
2. Check that gear oil level is not 8 mm (0.3 inch) below the bottom of filler plug
hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

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
Fig. 14: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3.
Tighten the filler plug to the specified torque.

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

Tightening torque: 49 +/- 9 N.m (37 +
/-6 f
t-lb)
WHEEL BEARING END PLAY CHECK 1. Remove the caliper assembly, and suspend the caliper assembly with a wire
and remove the brake disc.
2. Fit the dial gauge as shown in the diagram and move the hub in the axial
direction to measure the play.
Limit: 0.05 mm (0.002 inch)
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 15: Fitting The Dial Gauge To Hub Wheel

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. If the play exceeds the limit, replace the wheel bearing (Refer to TRAILING
ARM ).
4. Install the brake disc and caliper assembly, and tighten the caliper assembly
mounting bolts to the specified torque.

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

Tightening torque: 60 +/- 5 N.m (45 +
/-3 f
t-lb)
DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT Required Special Tools:
MB991380: Oil Seal Installer MB990938: Bar
1. Remove the drive shaft from the differential carrier (Refer to DRIVE SHAFT ASSEMBLY
).
2. Remove the differential carrier oil seal.

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