MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 116: Installing Oil Pump Using Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
71. Make sure that the input shaft end play meets the standard value.
Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch)

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 117: Measuring Input Shaft End Play

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
72. Install the oil filter.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 118: Installing Oil Filter

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
73. Use special tools MB990936 and MB990938 to tap the differential bearing
outer race in the transaxle case.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 119: Using Special Tools And Taping Differential Bearing Outer RaceCourtesy of MITSUBISHI MOTOR SALES OF AMERICA.
74. Install the differential

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 120: Installing Differential

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
75. Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch)
in diameter] on the tor
que converter housin
g as shown in the illustration

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 121: Placing Two Beads Of Solder On Torque Converter Housing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
76. Use special tools MB990936 and MB990938 to press in the differential bearing
outer race into the tor
que converter housin
g.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 122: Using Special Tools And Pressing In Differential Bearing Outer Race Into Torque Converter Housing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
77. Install the torque converter housing to the transaxle case without applying
sealant. Tighten its mounting bolts to the specified torque.
Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
78. Loosen all the bolts, and remove the torque converter housing. Then remove
the outer race and the crushed solders.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 123: Identifying Torque Converter Housing Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
79. Use a micrometer to measure the thickness of the crushed solder beads and
record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to
the measured value and select a spacer with the corresponding thickness.
Adjustment spacer sizes are all listed on SERVICE SPECIFICATIONS
.
Select the most suitable one from among those listed.
NOTE: *is the thickness for the differential case preload.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 124: Measuring Thickness Of Crushed Solder Beads

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
80. Install the spacer selected in step 79 to the torque converter housing.
81. Use special tools MB990936 and MB990938 to press the outer race into
housin
g.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 125: Using Special Tools And Pressing Outer Race Into Housing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
82. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine
Part number MD974421 or equivalent) to the torque converter housing in the
area shown.
NOTE: Be sure to install the case quickly while the sealant is
wet (with 15 minutes).
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