MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Spacer (For adjustment of output shaft preload)
Fig. 222: Spacer Identification Symbol Table (For Adjustment Of Output Shaft Preload)

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Spacer (For Adjustment Of Differential case preload)
Fig. 223: Spacer Identification Symbol Table (For adjustment of differential
case preload)

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Spacer (For Adjustment Of Backlash Between Differential Side Gear And
Pinion) < F4A5A >

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 224: Spacer Identification Symbol Table (For Adjustment Of Backlash Between Differential Side Gear And Pinion)

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Spacer (For adjustment of backlash between center differential side gear and
pinion) < W4A5A >
Fig. 225: Spacer Identification Symbol Table
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SEALANTS Fig. 226: Item Specified Sealants Table

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2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

2004 DRIVELINE/AXLES
Front Axle - Endeavor
GENERAL DESCRIPTION The front axle consists of front hubs, knuckles, wheel bearings and drive shafts, and
has the following features:
The wheel bearing incorporates a unit ball bearing (double-row angular contact
ball bearing) for reduced friction. The front wheel hub assembly combines the hub, wheel bearing, housing, and
oil seal in a single unit for fewer parts, better durability, improved assembly
precision, and better structural organization. The driveshaft incorporates BJ-PTJ type constant velocity joints< FWD>, BJ-
DOJ < AWD-LH>and BJ-TJ< AWD-RH> with high transmission efficiency
for low vibration and noise. Due to the use of the inner shaft and bracket assembly, the right and left drive
shafts are approximately the same in length. This reduces noise, vibration and
torque steer.< FWD> ABS rotor for detecting the wheel speeds is press-fitted to the rear hub in
vehicles with ABS.
CONSTRUCTION DIAGRAM NOTE:
PTJ: Pillow Tripod Joint BJ: Birfield Joint DOJ: Double Offset Joint TJ: Tripod Joint

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor


2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Fig. 1: Construction Diagram Of Front Axle (FWD)

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2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Fig. 2: Construction Diagram Of Front Axle (AWD)

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FRONT AXLE DIAGNOSIS TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you
will be sure that you have exhausted most of the possible ways to find a front axle
fault.
1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart. (See Fig. 3
)
4. Verify malfunction is eliminated.
SYMPTOM CHART
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Fig. 3: Drive Shaft Troubleshooting Symptom Chart

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SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: Noise During Wheel Rotation DIAGNOSIS
STEP 1. Check the wheel bearing end play.
1. Remove the caliper assembly and suspend it with a wire.
2. Remove the brake disc from the front hub.
3. Attach a dial gauge as shown in the illustration, and then measure the end
play while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
Q: Is the wheel bearing end play within the limit?
YES: Go to step 2.
NO: Replace the part, then go to Step
5.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Fig. 4: Measuring Wheel Bearing End Play Using Dial Gauge

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STEP 2. Check the drive shaft and inner shaft for bending.
Q: Is the drive shaft and inner shaft bent?
YES: Replace the part. Then go to Step 5 .
NO: Go to step 3.
STEP 3. Check the center bearing for wear.
Q: Is the center bearing worn?
YES: Replace the bearing. Then go to Step 5 .
NO: Go to step 4.
STEP 4. Check the drive shaft assembly for wear or damage.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Q: Is the drive shaft assembly worn or damaged?
YES: Replace the drive shaft assembly. Then go to Step 5.
NO: There is no action to be taken.
STEP 5. Retest the system.
Q: Is the abnormal noise eliminated?
NO: Repeat to Step 1 .
YES: The procedure is complete.
INSPECTION PROCEDURE 2: Noise Due To Excessive Play Of Wheel In Turning Direction DIAGNOSIS
STEP 1. Check for play in the inner shaft and side gear serration, the
drive shaft and side gear serration, or the drive shaft and front hub
serration.
Q: Is the play found?
YES: Replace the part. Then go to Step 2.
NO: The procedure is complete.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
NO: Repeat to Step 1.
YES: The procedure is complete.
SPECIAL TOOLS
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Fig. 5: Special Tools Description Chart (1 Of 3)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor

Fig. 6: Special Tools Description Chart (2 Of 3)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle - Endeavor