MITSUBISHI ENDEAVOR 2004 Service Repair Manual

MB991522(MB991526): Torsion Bar Bushing Remover and Installer (Installer
Guide)
1. Use special tool MB991448 to remove the bushing.
Fig. 45: Removing Bushing

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2. Use special tool MB991526 to press-fit the bushing until the bushing outer
case end face is flush with the differential mount
bracket.

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

Fig. 46: Pressing Bushing

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

Fig. 47: Exploded View Differential Carrier Assembly Components

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Required Special Tools:
MB
990909:
Wo
rkin
g Base


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

MB991116: Working Base Adapter MB990939: Brass Bar MB990810: Side Bearing Puller MB990811: Side Bearing Cup MB990850: End Yoke Holder MB998801: Remover
DISASSEMBLY SERVICE POINTS <> INSPECTION BEFORE DISASSEMBLY 1. Remove the cover.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 48: Removing Cover

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2. Hold special tools MB990909 and MB991116 in a vise, and install the
differential carrier assembly to the special tool.
FINAL DRIVE GEAR BACKLASH 1. With the drive pinion locked in place, use a dial gauge to measure the drive
gear backlash in four or more places on the drive gear.
Standard value: 0.11 - 0.16 mm (0.004 - 0.006 inch)
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 49: Measuring Final Drive Gear Backlash

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. If the backlash is not within the standard value, adjust the final drive gear
backlash (Refer to ASSEMBLY
).
3. After the adjustment, inspect the final drive gear tooth contact.
DRIVE GEAR RUNOUT
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

1. Measure the drive gear runout at the shoulder on the reverse side of the drive
gear.
Limit: 0.05 mm (0.002 inch)
Fig. 50: Measuring Drive Gear Runout

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. When runout exceeds the limit value, check for forei
gn material between drive

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

gear rear side and differential case, or for loose drive gear installation bolts.
3. When step (2) gives normal results, reposition the drive gear and differential
case and remeasure.
4. If adjustment is impossible, replace the differential case, or replace the drive
gear and pinion as a set.
DIFFERENTIAL GEAR BACKLASH 1. Insert a wedge between the side gear and the pinion shaft to lock the side gear.
2. While locking the side gear with the wedge, measure the differential gear
backlash with a dial indicator on the pinion gear.
Use the measurement procedure for the other pinion gear.
Standard value: 0,01 - 0.250 mm (0.0004 - 0.0098 inch)
Limit: 0.2 mm (0.01 inch)
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 51: Measuring Differential Gear Backlas
h
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. If the backlash exceeds the limit value, adjust it by replacing the side gear
spacers.
4. If adjustment is not possible, replace the side gears and pinion gears as a set.
FINAL DRIVE GEAR TOOTH CONTACT Check the tooth contact of drive gear by following the steps below.
1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear
teeth.
Fig. 52: Applying Thin Uniform Coat Of Machine Blue To Both Surfaces
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Of The Drive Gear Teet
h
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2. Insert special tool MB990939 between the differential carrier and the
differential case, and then rotate the companion flange by hand (once in the
normal direction, and then once in the reverse direction) while applying a load
to the drive gear so that the revolution torque [approximately 2.5 - 3.0 N.m
(22.1 - 26.6 i
n-lb)] is applied to the drive pinion.
CAUTION: If the drive gear is rotated too much, the tooth
contact pattern will become unclear and difficult
to check.

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