MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 83: Turning Torque Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. If the turning torque is not within the standard value, check the tightening
torque of the companion flange self-locking nut, and the installation of the oil
seal.
>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear spacers, pinion gears, and pinion washers
into the differential case.
Fig. 84: Assembling Side Gears, Spacers, Pinion Gears & Washers Into
Differential Case

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

2. Temporarily install the pinion shaft.
3. Insert a wedge between the side gear and the pinion shaft to lock the side gear.
4. While locking the side gear with the wedge, measure the differential gear
backlash with a dial indicator on the pinion gear.
Measure by the same procedure for the other pinion gear.
Standard value: 0.01 - 0.250 mm (0.0004 - 0.0098 inch)
Limit: 0.2 mm (0.01 inch)
Fig. 85: Measuring Differential Gear Backlash With Dial Indicator

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NOTE: Do not assemble the lock pin yet.

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

5. If the backlash exceeds the limit value, adjust it by replacing the side gear
spacers.
6. If adjustment is not possible, replace the side gears and pinion gears as a set.
7. Check that the backlash is within the limit value and that the differential gear
turns smoothly. >>G<< LOCK PIN INSTALLATION 1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and
drive in the lock pin.
2. Stake the lock pin with a punch on both sides.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 86: Staking Lock Pin With Punch

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>>H<< DRIVE GEAR INSTALLATION 1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the drive gear by turning
the tap (M 10 X 1.25). Clean the threaded holes by applying compressed air.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 87: Removing Adhesive Adhered To Threaded Holes Of Drive Gear By Turning Tap

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3. Apply 3M
TM
stud locking 8730, 8731 or equivalent to the threaded holes of
the drive
gear.

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

Fig. 88: Applying Stud Locking Or Equivalent To Threaded Holes Of Drive Gear

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4. Install the drive gear onto the differential case with the mating marks properly
aligned. Tighten the drive gear attaching bolts to the specified torque in a
diagonal sequence.
Tightening torque: 84 +/- 4 N.m (62 +/- 3 ft-lb)
>>I<< DIFFERENTIAL SIDE BEARING INNER RACE INSTALLATION Use special tool MB990728 to press-fit the differential side bearing inner races into
the differential case.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 89: Installing Differential Side Bearing Inner Race

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>>J<< DIFFERENTIAL SIDE BEARING NUT INSTALLATION/SNAP RING & FINAL DRIVE GEAR BACKLASH
ADJUSTMENT Adjust the final drive gear backlash by the following procedure:
1. Using special tools MB991367 and MB991385, temporarily tighten the side
bearin
g nut to
just before
preloadin
g of the side bearin
g.

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

Fig. 90: Tightening Side Bearing Nut

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2. Measure the final drive gear backlash at four points or more on the
circumference of the drive gear.
Standard value: 0.11 - 0.16 mm (0.004 - 0.006 inch)

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

Fig. 91: Measuring Final Drive Gear Backlash

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3. Using special tools MB991367, MB991385, adjust the backlash to standard
value by moving the side bearing nut as shown.
NOTE: First loosen the side bearing nut then tighten the side
bearing nut the same amount as when it was loosened.

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

Fig. 92: Adjusting Backlash To Standard Value By Moving Side Bearing Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Using special tools MB991367 and MB991385, apply the preload, turn down
both right and left side bearing nuts on half the distance between centers of two
neighboring holes.

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