MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 37: Removing DOJ Cage From DOJ Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<> DOJ BOOT/BJ BOOT REMOVAL Wrap plastic tape around the spline part on the DOJ side of the drive shaft so that
DOJ boot/BJ boot are not dama
ged when the
y are removed.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 38: Identifying DOJ Boot/BJ Boot

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ASSEMBLY SERVICE POINTS >>A<< BJ BOOT/DOJ BOOT INSTALLATION 1. Wrap the tape around the spline of the shaft, then install BJ boot and DOJ boot
in order.
2. Fill the inside of BJ and BJ boot with specified grease.
Specified grease: Repair kit grease
Used amount: 75 +/- 10 g (2.6 +/- 0.3 oz)
CAUTION: Do not mix old and new or different types of
grease, as a special grease is used in the joint.
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 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 39: Filling Grease Inside Boot

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Tighten the boot band.
>>B< 2. Align the mating mark of DOJ inner race with that of the shaft.
CAUTION: In order to fill the specified amount of air inside
the BJ boot, keep the bent angle of the drive
shaft to C° during the operation.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 40: Aligning Mating Mark Of DOJ Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Tap the inner race with even force to press-fit into the bump of the shaft with
special tool MB990939.
>>C< Specified grease: Repair kit grease
Used amount: 90 +
/- 10
g (3.2 +
/- 0.3 oz)
CAUTION: The drive shaft joint use special grease. Do not mix
old and new or different types of grease.

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 41: Filling Grease Inside Boot

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>D>> DOJ BOOT/DOJ BOOT BAND INSTALLATION 1. Position the DOJ outer race so that the distance between the boot bands is at
the standard value.
Standard value (A): 90 +/- 3 mm (3.5 +/- 0.1 inches)
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 42: Positioning DOJ Outer Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Remove part of the DOJ boot from the DOJ outer race to release the air
pressure inside the boot.
DIFFERENTIAL CARRIER ASSEMBLY REMOVAL AND INSTALLATION
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 43: Removing/Installing Differential Carrier Assembly Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REMOVAL SERVICE POINTS <> PROPELLER SHAFT DISCONNECTION 1. Make mating marks on the differential companion flange and the propeller
shaft assembly.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 44: Mating Marks On Differential Companion Flange

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Suspend the removed propeller shaft from the body with a wire to prevent
bending.
INSTALLATION SERVICE POINTS >>A<< PROPELLER SHAFT INSTALLATION Align the mating marks of differential companion flange and propeller shaft
assembly. DIFFERENTIAL MOUNT BRACKET BUSHING REPLACEMENT Required Special Tools:
MB991448: Bush Remover and Installer Base

2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor