Rear suspension MITSUBISHI ENDEAVOR 2004 Service Manual PDF

Fig. 43: Removing/Installing Differential Carrier Assembly Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REMOVAL SERVICE POINTS <> PROPELLER SHAFT DISCONNECTION 1. Make mating marks on the differential companion flange and the propeller
shaft assembly.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 44: Mating Marks On Differential Companion Flange

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Suspend the removed propeller shaft from the body with a wire to prevent
bending.
INSTALLATION SERVICE POINTS >>A<< PROPELLER SHAFT INSTALLATION Align the mating marks of differential companion flange and propeller shaft
assembly. DIFFERENTIAL MOUNT BRACKET BUSHING REPLACEMENT Required Special Tools:
MB991448: Bush Remover and Installer Base

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

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

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISASSEMBLY
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 47: Exploded View Differential Carrier Assembly Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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