MITSUBISHI ENDEAVOR 2004 Service Repair Manual

DISASSEMBLY AND ASSEMBLYFig. 147: Disassembling And Assembling View Of Oil Pump

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Required Special Tool:
MD998334: Oil Seal Installer

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 148: Identifying Oil Seal Installer

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ASSEMBLY SERVICE POINTS >>A<< OIL SEAL INSTALLATION 1. Apply a small amount of ATF to the oil seal lip.
2. Use special tool MD998334 to tap the oil seal in the oil pump body.
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

>>B<<
O-RING INSTALLATION
Install a new O-ring to the outer groove of the oil pump, and apply ATF or
petroleum jelly (Vaseline) to the O-ring. UNDERDRIVE CLUTCH AND INPUT SHAFT DISASSEMBLY AND ASSEMBLY Fig. 149: Disassembling And Assembling View Of Underdrive Clutch And Input Shaft

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

MB991629: Spring Compressor MD998907: Spring Compressor MD998924: Spring Compressor Retainer
DISASSEMBLY SERVICE POINT << A >> SNAP RING REMOVAL 1. Set special tools MD998907 and MD998924 as shown in the illustration.
2. Compress the return spring and remove the snap ring.
Fi
g. 150: Usin
g Special Tools And Removin
g Sna
p Rin
g

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
.
ASSEMBLY SERVICE POINTS >>A<< D-RING INSTALLATION 1. Install a D-ring in the groove in the underdrive clutch retainer and piston, and
in the groove in the outside of the spring retainer. Be careful not to twist or
damage the D-rings.
2. Apply ATF or petroleum jelly (Vaseline) to the D-rings.
Fig. 151: Installing D
-Ring In Groove In Underdrive Clutch Retainer

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>>B<< SNAP RING INSTALLATION 1. Place the snap ring on top of the spring retainer, and then set special tool
MD998907 as shown in the illustration.
2. Com
press the return s
prin
g and install the sna
p rin
g.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 152: Installing Snap Ring

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>>C<< CLUTCH PLATE/CLUTCH DISC/CLUTCH REACTION PLATE INSTALLATION 1. Assemble the four clutch plates and four clutch discs one on top of the other
inside the underdrive clutch retainer. All four clutch plates should be
assembled so that the places with no teeth (marked "A") are aligned with the
CAUTION: Immerse the clutch disc in ATF before assembling it.
IF the clutch disc is new, soak it in ATF for at least
two hours.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

holes in the retainer (marked "B").
2. Install the clutch reaction plate in the direction shown. in stall it the same as the
clutch plates, so that the areas with no teeth (marked "A") are aligned with the
retainer (marked "B")
Fig. 153: Placing With No Teeth Are Aligning With Holes In Retainer

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2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 154: Installing Clutch Reaction Plate In Direction

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>>D<< SNAP RING INSTALLATION 1. Install the snap ring into the groove of clutch retainer.
2. Set special tools MB991629 and MD998924 as shown in the illustration, and
then compress the clutch element.
3. Check that the clearance between the snap ring and the clutch reaction plate is
within the standard value. If not within the standard value, select a snap ring so
that it is.
Standard value: 1.6 - 1.8 mm (0.0630 - 0.0709 inch)
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 155: Installing Snap Ring

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REVERSE AND OVERDRIVE CLUTCH DISASSEMBLY AND ASSEMBLY NUMBER OF CLUTCH DISCS AND PLATES Fig. 156: Number Of Clutch Discs And Plates Table

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2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 157: Exploded View Of Reverse And Overdrive Clutch

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Required Special Tools:
MB991629: Spring Compressor MB991789: Spring Compressor MD998924: Spring Compressor Retainer MD999575: S
prin
g Com
pressor

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor