MITSUBISHI ENDEAVOR 2004 Service Repair Manual

Fig. 177: Installing Transfer Driven Gear

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 178: Disassembly And Assembly View Of Differential

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:
MD998801: Bearing Remover MD998812: Installer Cap MD998820: Installer Adapter (42)
DISASSEMBLY SERVICE POINT << A >> TAPER ROLLER BEARING REMOVAL 1. Support the taper roller bearing with special tool MD998801, and then set them
on the
press.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

2. Push down on the differential case with the press to remove the bearing.
Fig. 179: Removing Bearing With Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ASSEMBLY SERVICE POINTS >>A<< SPACER, SIDE GEAR, WASHER, PINION AND PINION SHAFT INSTALLATION 1. Mount a spacer on the back surface of the side gear, and then install the side
gear in the differential case.
NOTE: When a new side gear is to be installed, mount a
medium thickness spacer [0.93 to 1.00 mm (0.0366 to
0.0395 inch)].

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

2. Set the washer on the back of each pinion, and put both pinions simultaneously
in mesh with the side gears. While rotating them, install them into position.
Fig. 180: Installing Pinion

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3. Insert the pinion shaft.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 181: Inserting Pinion Shaft

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Measure the backlash between the side gear and pinion.
Standard value:
0.025 - 0.150 mm (0.0010 - 0.0059 inch)
5. If the backlash is out of the standard value, select a spacer and re-measure the
backlash.
NOTE: Adjust until the backlashes on both sides are equal.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 182: Measuring Backlash Between Side Gear And Pinion

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>B<< LOCK PIN INSTALLATION Install the lock pin so that it will be oriented in the direction shown.
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 183: Installing Lock Pin

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>C<< TAPER ROLLER BEARING INSTALLATION Using special tools MD998812 and MD998820, press in the taper roller bearing
with the
press.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 184: Using Special Tools And Installing Roller Bearing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>D<< DIFFERENTIAL DRIVE GEAR INSTALLATION Apply ATF to the bolts, and then tighten the bolts to the specified torque in the
shown sequence.
Tightening torque: 132 +/- 5 N.m (98 +/- 4 ft-lb)
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 185: Identif
ying Ti
ghtenin
g Tor
que Se
quence In Bolt Of Differential Drive
Gear

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CENTER DIFFERENTIAL DISASSEMBLY AND ASSEMBLY < W4A5A >
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 186: Disassembly And Assembly View Of Center Differential

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:
MD998812: Installer Cap MD998917: Bearing Remover MB990930: Installer Adapter MD998824: Installer Adapter (50) MB990937: Installer Adapter
DISASSEMBLY SERVICE POINTS
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor