MITSUBISHI ENDEAVOR 2004 Service Repair Manual

kg/cm
2 )
ThermostatStarts To Open
187-193°F (86.5-89.5°
C)
Fully Opens
212°F (100°C)

2004 Mitsubishi Endeavor Limited
2004 ENGINE COOLING Specifications & Drive Belt Routing - Endeavor

2004 DRIVELINE/AXL
E
Propeller Shaft - Endeavor
GENERAL DESCRIPTION For AWD vehicles, 3 way split 4-joint type propeller shaft with center bearing is
adopted, and it has the following features.
The DOJ, which is of less sliding resistance, is used for the No.3 joint. This
reduces the idling vibration. A insulator is located at the center bearing to vehicle body joint, reducing
vibration.
CONSTRUCTION DIAGRAM Fig. 1: Identifying Construction Diagram Of Propeller Shaft

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PROPELLER SHAFT DIAGNOSIS INTRODUCTION TO PROPELLER SHAFT DIAGNOSIS If an abnormal noise is heard from the propeller shaft while driving, some parts of
the
propeller shaft ma
y be worn or dama
ged, or some mountin
g bolts ma
y be loose.
NOTE: DOJ: Double Offset Joint
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor


2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

PROPELLER SHAFT DIAGNOSTIC TROUBLESHOOTING STRATEGYUse these steps to plan your diagnostic strategy. If you follow them carefully, you
will be sure that you have exhausted all of the possible ways to find a propeller
shaft 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.
4. Verify malfunction is eliminated. SYMPTOM CHART Fig. 2: Propeller Shaft Troubleshooting Symptom Chart

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SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: Noise at Start DIAGNOSIS
STEP 1. Check if the propeller shaft and differential companion flange
connecting nuts and the center bearing mounting nuts are loose.
Connecting nuts tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)
Mounting nuts tightening torque: 30 +/- 4 N.m (22 +/- 3 ft-lb)
Q: Are the connecting nuts and mounting nuts tightened to the specified
torque?
YES: Go to Ste
p 2.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

NO: Tighten the connecting nuts and mounting nuts to the specified
torque. Then go to Step 3 .
STEP 2. Check the sleeve yoke's spline of front propeller shaft for wear.
Q: Is wear apparent?
YES: Replace the propeller shaft. Then go to Step 3.
NO: Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Recheck from Step 1 .
INSPECTION PROCEDURE 2: Noise and Vibration at High Speed DIAGNOSIS
STEP 1. Check the propeller shaft run-out.
1. Remove the propeller shaft. (Refer to PROPELLER SHAFT
.)
2. Measure the propeller shaft runout.
Limit: 0.6 mm (0.02 inch)

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

Fig. 3: Measuring Propeller Shaft Runout

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the measured value within the limit: 1.0 mm (0.04 inch)?
YES: Go to Step 2.
NO: Replace the propeller shaft. Then go to Step 2.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Recheck from Ste
p 1.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

PROPELLER SHAFT REMOVAL AND INSTALLATION Fig. 4: Removing And Installing Propeller Shaft

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REMOVAL SERVICE POINT << A>> PROPELLER SHAFT ASSEMBLY REMOVAL 1. Make mating marks on the differential companion flange and the propeller
shaft assembl
y.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

Fig. 5: Identifying Mating Marks On Differential Companion Flange And Propeller Shaft Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Insert a rag so as to avoid boot damage, and remove the propeller shaft
assembly in a straight and level manner.
CAUTION: Be careful not to bend the joint assembly when
removing the propeller shaft because this may
cause damage to the joint boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

Fig. 6: Inserting Rag

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INSTALLATION SERVICE POINT << A>> PROPELLER SHAFT ASSEMBLY INSTALLATION
CAUTION:
Do not dama
ge the oil seal lips on the transfer ca
s

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

If reusing the propeller shaft, align the mating marks of differential companion
flan
ge and
propeller shaft assembl
y to install.
Fig. 7: Locating Oil Seal Lips On Transfer Case

Courtes
y of MITSUBISHI MOTOR SALES OF AME
R
Remove oil and grease from the threads of the
mounting bolts and nuts before ti
ghtenin
g, or the
y
loosen. Be careful not to bend the
joint portion when rem
o
the propeller shaft, because this will damage the j
o
boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

Fig. 8: Aligning Mating Marks Of Differential Companion Flange And Propeller Shaft Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSPECTION
Check the sleeve yoke and center yoke for wear, damage or cracks. Check the propeller shaft for bends, twisting or damage. Check the universal joint for smooth operation in all directions. Check the center bearing for smooth movement.
PROPELLER SHAFT RUNOUT
Limit: 0.6 mm (0.02 inch)

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor