MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 106: Installing Rear Cover Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
56. Install the underdrive clutch hub to the underdrive sun gear.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 107: Installing Underdrive Clutch Hub To Underdrive Sun Gear

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
57. Check the installation direction of thrust bearing number 2, and install it on the
underdrive clutch hub.
CAUTION: Be sure to install the thrust bearing in the correct
direction as shown.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 108: Installing Thrust Bearing Number 2

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
58. Hold the in
put shaft, and install the underdrive clutch.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 109: Installing Underdrive Clutch

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
59. Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14
inch) in diameter] on the underdrive clutch retainer as shown in the illustration.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 110: Placing Two Beads Of Solder On Underdrive Clutch Retainer

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
60. Install special tool MD998412 as shown.
61. Install the oil pump to the transaxle case.
62. Tighten the oil pump mounting bolts (six pieces) to the specified torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)
NOTE: Do not install the oil pump gasket at this time.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 111: Installing Special Tool MD998412

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
63. Remove the oil pump mounting bolts.
64. Using special tools MD998333, remove the oil pump and the crushed solders.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 112: Using Special Tools And Removing Oil Pump

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
65. Use a micrometer to measure the thickness of the crushed solder beads and
record the measured value.
66. Select a thrust washer number 1 whose thickness corresponds to the measured
value from table below.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 113: Measuring Thickness Of Crushed Solder Beads

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 114: Thrust Washer Thickness Measurement Value Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
67. Install thrust washer number 1 that was selected in step 65 on the underdrive
clutch retainer.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 115: Installing Thrust Washer Number 1

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
68. Install special tool MD998412 as shown.
69. Install the new oil pump gasket on the transaxle case.
70. Install the oil pump and tighten the mounting bolts (six pieces) to the specified
torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor