MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 53: Rotating Companion Flange

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Check the tooth contact condition of the drive
gear and drive
pinion.

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

Fig. 54: Tooth Contact Pattern Specification Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<B>> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL SIDE BEARING SPACER/DIFFERENTIAL SIDE BEARING
OUTER RACE REMOVAL NOTE: Check the tooth contact pattern to confirm that the
adjustments of the pinion height and backlash have been
done properly. Continue to adjust the pinion height and
backlash until the tooth contact pattern resembles the
standard pattern. If, even after adjustments have been
made, the correct tooth contact pattern cannot be obtained,
it means that the drive gear and the drive pinion have
become worn beyond the allowable limit. Replace the gear
set.
CAUTION: When taking out the differential case assembly, be
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Use the wooden handle of a hammer to remove the differential case assembly,
differential side bearing spacers and differential side bearing outer races.
Fig. 55: Removing Differential Case Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
careful not to drop and damage the differential side
bearing spacers and differential side bearing outer
races.
NOTE: Keep the right and left side bearings and side bearing
spacers separate, so that they do not become mixed during
reassembly.

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

<<C>> DIFFERENTIAL SIDE BEARING INNER RACE REMOVALUse special tools MB990810 and MB990811 to pull out the side bearing inner
races.
Fig. 56: Pulling Out Side Bearing Inner Races

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<D>> DRIVE GEAR REMOVAL 1. Make the mating marks to the differential case and the drive gear.
2. Loosen the drive gear attaching bolts in a diagonal sequence to remove the
drive
gear.
NOTE: There are two notches provided (at the differential case
side) for the claw part of the special tools; use special tool
MB990810 at that position.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 57: Loosening Drive Gear Attaching Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<E>> LOCK PIN REMOVAL Drive out the lock
pin with a
punch.

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

Fig. 58: Driving Out Lock Pin With Punch

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<F>> SELF-LOCKING NUT REMOVAL Use special tool MB990850 to hold the companion flange, and then remove the
companion flange self-locking nut.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 59: Removing Companion Flange Self Locking Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<G>> DRIVE PINION ASSEMBLY/COMPANION FLANGE REMOVAL 1. Make mating marks on the drive pinion and companion flange.
2. Use s
pecial tool MB990810 to
pull out the com
panion flan
ge.
CAUTION: The mating mark made on the companion flange
must not be on the coupling surface of the
companion flange and the front propeller shaft.

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

Fig. 60: Removing Pinion Assembly/Companion Flange

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<H>> DRIVE PINION REAR BEARING INNER RACE REMOVAL Use special tool MD998801 to pull out the drive pinion rear bearing inner race.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 61: Pulling Out Drive Pinion Rear Bearing Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<I>> OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE
REMOVAL Use special tool MB990939 to remove the oil seal, drive pinion front bearing inner
race, and drive pinion front bearing outer race.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 62: Removing Oil Seal, Drive Pinion Front Bearing Inner Race, Drive Pinion Front Bearing Outer Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<<J>> DRIVE PINION REAR BEARING OUTER RACE REMOVAL Use s
pecial tool MB990939 to remove the drive
pinion rear bearin
g outer race.

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