boot MITSUBISHI ENDEAVOR 2004 Service User Guide

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

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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

2. Using special tool MB990767, tighten the drive shaft nut to the specified
torque 236 +/- 19 N.m (174 +/- 14 ft-lb).
Fig. 24: Tightening Drive Shaft Nut Using Special Tool MB990767

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DISASSEMBLY AND ASSEMBLY < FWD>
damaged.
CAUTION:
For vehicles with ABS, be careful not to damage
the ABS rotor, which is attached to the BJ outer
race during disassembly and reassembly. Never disassemble the BJ assembl
y except when
replacing the BJ boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 25: Disassembling BJ Inner Shaft (FWD)

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NOTE:
PTJ: Pillow Tripod Joint BJ: Birfield Joint For BJ boot removal and installation, refer to BJ BOOT

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Required Special Tools:
MB991248 or MD998801: Inner Shaft Remover MB990810: Side Bearing Puller MB990930: Installer Adapter MB990932: Installer Adapter MB990934: Installer Adapter MB990938: Bar (snap-in type) MB990890: Rear Suspension Bushing Base MB991172: Inner Shaft Installer Base
LUBRICATION POINTS
(RESIN BOOT) REPLACEMENT
.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 29: Removin
g Center Bearin
g From Center Bearin
g Bracket Usin
g Special
Tools

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<< D>> PTJ BOOT REMOVAL 1. Wipe off grease from the shaft spline.
2. When reusing the PTJ boot, wrap plastic tape around the shaft spline to avoid
damaging the boot. ASSEMBLY SERVICE POINTS >>A<< PTJ BOOT INSTALLATION Wrap plastic tape around the shaft spline, and then install the PTJ boot band (small)
and PTJ boot.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 35: Pressing Inner Shaft Into PTJ Case

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>>F<< PTJ CASE INSTALLATION After applying the specified grease to the PTJ case, insert the drive shaft and apply
grease again.
Specified grease: Repair kit grease
Amount to use: 220 +/- 10 g (7.8 +/- 0.3 ounces)
CAUTION: The drive shaft joint use special grease. Do not mix
old and new or different types of grease.
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 36: Identifying Grease Area In PTJ Case

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>>G<< PTJ BOOT BAND (SMALL) /PTJ BOOT BAND (LARGE) INSTALLATION Set the PTJ boot bands at the specified distance in order to adjust the amount of air
inside the PTJ boot, and then tighten the PTJ boot band (small), PTJ boot band
(large) securely.
Standard value (A): 85 +/- 3 mm (3.35 +/- 0.12 inches)
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 37: Identifying PTJ Boot Dimension

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INSPECTION
Check the drive shaft for damage, bending or corrosion. Check the inner shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the inner shaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside PTJ case for wear or corrosion. Check the boots for deterioration, damage or cracking. Check the center bearing for seizure, discoloration or roughness of rolling
surface. Check the dust cover for damage or deterioration.
DISASSEMBLY AND REASSEMBLY
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

CAUTION:
For vehicles with ABS, be careful not to damage
the ABS rotor, which is attached to the BJ outer
race during disassembly and reassembly. Never disassemble the BJ assembly except when
replacing the BJ boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 38: Disassembling BJ Drive Shaft (AWD)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
LUBRICATION POINTS Fig. 39: Identifying Lubrication Points (1 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
NOTE:
BJ: Birfield Joint DOJ: Double Offset Joint TJ: Tripod Joint For BJ boot removal and installation, refer to BJ BOOT (RESIN BOOT) REPLACEMENT
.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor