MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 96: Installing Return Spring And Second Brake Piston

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44. Install the sna
p rin
g.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 97: Installing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
45. Check the installation direction of the thrust bearing number 5, and install it on
the hub of the
planetar
y reverse sun
gear.
CAUTION: Be sure to install the thrust bearing in the correct
direction as shown.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 98: Installing Thrust Bearing Number 5 In Direction

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46. Attach thrust bearing number 6 to the inside of the overdrive clutch hub using
petroleum jelly (Vaseline). Then install the assembly in the reverse and
overdrive clutch.
CAUTION: Use care to install the thrust bearing in the
proper direction.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 99: Attaching Thrust Bearing Number 6 To Inside Of Overdrive Clutch Hub

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47. Install the reverse and overdrive clutch.
48. Check the installation direction of thrust bearing number 7 and install it on the
reverse clutch retainer.
CAUTION: Be sure to install the thrust bearing in the correct
direction as shown.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 100: Checking Installation Direction Of Thrust Bearing Number 7

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
49. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
50. Install the four seal rin
gs in the
grooves of the
rear cover.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 101: Using Special Tool To Taping Input Shaft Rear Bearing In Rear Cover

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
51. Measure the end play of the under drive sun gear by the following procedures:
1. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch);
part number MD707267] on thrust bearing number 7.
2. Install the rear cover on the transaxle case and tighten the bolts to the
specified tor
que.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Tightening torque: 23 +
/- 3 N.m (17 +
/- 2 f
t-lb)
3. Turn over the transaxle case so that the installation surface of the torque
converter housing is facing up.
4. Install the under drive clutch hub on the under drive sun gear.
5. Measure end play of the underdrive sun gear and record the measurement
value.
Standard value (Reference): 0.25 - 0.45 mm (0.0098 - 0.0177 inch)
6. After taking the measurements in steps (1) to (4), take out the installed
parts.
Fig. 102: Measuring End Play Of Under Drive Sun Gear

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2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

52. Install the three O-rings.
53. Select a thrust race number 8 whose thickness corresponds to the measured
values taken in step 50 from the table below. Install it on thrust bearing number
7.
Fig. 103: Installing Three O
-Rings

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2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 104: Thrust Race Thickness Measurement Values Table

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54. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine
Part number MD974421 or equivalent) to the illustrated position of the rear
cover.
NOTE: Be sure to install the case quickly while the sealant is
wet (within 15 minutes).

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 105: Applying Bead Of Sealant

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55. Install the rear cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
NOTE: After installation, keep the sealed area away from the oil
for approximately one hour.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor