differential MITSUBISHI ENDEAVOR 2004 Service Service Manual

to-10°F): SAE 80W, 80W-90, Below-34°C (-30°F): SAE 75W. Then go to
Step 3 .
NO: Go to Step 2.
STEP 2. Check for excessive gear backlash (Refer to DISASSEMBLY
).
Q: Is the gear backlash correct?
YES: Go to Step 3.
NO: Adjust the backlash. Then go to step 3.
STEP 3. Retest the system.
Q: Is the heat eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 8: OIL LEAKAGE {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the cover installation.
Q: Is the cover installed correctly?
YES: Go to Step 2.
NO: Repair. Then go to Step 4 .
STEP 2. Check the oil seal for wear or damage.
Q: Is the oil seal worn or damaged?
YES: Replace the seal. Then go to Step 4 .
NO: Go to Step 3.
STEP 3. Check the oil level.
Remove the filler
plug and check the
gear oil level.

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

Fig. 11: Identifying Special Tools (4 Of 4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ON-VEHICLE SERVICE REAR AXLE TOTAL BACKLASH CHECK 1. Park the vehicle on a flat, level surface.
2. Place the selector lever to the neutral position. Apply the parking brake and
jack up the vehicle.
3. Turn the propeller shaft clockwise as far as it will go. Make the mating marks
on the dust cover of the com
panion flan
ge and on the differential carrier.

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

Fig. 13: Measuring Distance Between Mating Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. If the backlash exceeds the limit value, remove the differential carrier assembly
and check the following.
Final drive gear backlash (Refer to DISASSEMBLY
).
Differential gear backlash (Refer to DISASSEMBLY
).
GEAR OIL LEVEL CHECK 1. Remove the filler plug.
2. Check that gear oil level is not 8 mm (0.3 inch) below the bottom of filler plug
hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Tightening torque: 60 +/- 5 N.m (45 +
/-3 f
t-lb)
DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT Required Special Tools:
MB991380: Oil Seal Installer MB990938: Bar
1. Remove the drive shaft from the differential carrier (Refer to DRIVE SHAFT ASSEMBLY
).
2. Remove the differential carrier oil seal.

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

Fig. 16: Removing Differential Carrier Oil Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Use special tools MB990938 and MB991380 to press-fit a new oil seal.
4. Apply multi-purpose grease to the oil seal lip and drive shaft oil seal seating
area.
5. Replace the drive shaft circlip with a new one, and install the drive shaft to the
differential carrier
(Refer to DRIVE SHAFT ASSEMBLY
).

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

<> DRIVE SHAFT REMOVA
L
1. Use special tools MB990242, MB990244, MB991354 and MB990767 to push
out the drive shaft from the hub.
Fig. 30: Pusing Out Drive Shaft From Hub

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
Do not pull on the drive shaft; doing so will
damage the TJ; be sure to use special tools
MB991721, MB991833 and MB991961. When pulling the drive shaft out from the
differential carrier, be careful that the spline
part of the drive shaft does not damage the
oil seal.

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