MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 55: Removing Remaining Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
56. Remove the transfer drive
gear.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 56: Removing Transfer Drive Gear

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
57. Remove the cap by inserting a screw driver into the center of the cap and
prying it u
p.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 57: Removing Cap By Inserting A Screw Driver

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
58. Using a chisel, remove the staked nut from the output shaft.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 58: Using Chisel And Removing Staked Nut From Output Shaft

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
59. Use special tools MB991625 and MB990607 to remove the output shaft jam
nut.
CAUTION: The jam nut is reverse threaded.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 59: Using Special Tools And Removing Output Shaft Jam Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
60. Remove the bearin
g retainer mountin
g bolts.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 60: Removing Bearing Retainer Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
61. Tap on the rear end of the output shaft to remove the output shaft, taper roller
bearing and collar.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 61: Removing Output Shaft Taper Roller Bearing And Collar

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
62. Remove the outer race and the spacer.
63. Remove the snap ring.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 62: Removing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ASSEMBLY
CAUTION:
Do not reuse the gasket, O-ring, oil seal. Always
replace with a new one when assembling. Do not use grease other than petroleum jelly
(Vaseline). Apply ATF to friction components, rotating parts,
and sliding parts before installation. Immerse a
new clutch disc or brake disc in ATF for at least
two hours before assembling them. When replacing a bushing, replace the assembly
which it belongs to.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

1. Install special tool MD998412 in the installation screw hole of the transfer
drive gear bearing located in the transaxle case. Using this as a guide, install
the transfer drive gear bearing and gear in the transaxle case.
Fig. 63: Installing Special Tool In Installation Screw Hole Of Transfer
Drive Gear Bearing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Tighten the eight mounting bolts of the transfer drive gear bearing to the
s
pecified tor
que.
Do not use cloth gloves or shop towels during
assembly. Use nylon cloth or other lint-free
material.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Tightening torque : 34 +
/- 2 N-m (25 +
/-1 f
t-lb)
Fig. 64: Tightening Mounting Bolts Of Transfer Drive Gear Bearing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Install the low-reverse brake piston, return spring, and spring retainer into the
transaxle case.
4. Fit a new O-ring into the groove of one-way clutch inner race.
5. Check the placement of the identification notches in the one-way clutch inner
race. Install the one-way clutch inner race to the transfer drive gear bearing so
that the notches fall alon
g the A - A line.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor