MITSUBISHI ENDEAVOR 2004 Service Repair Manual

A. Remove the balls from the DOJ cage. See Fig. 6
.
B. Remove the DOJ cage from the DOJ inner race in the direction of the BJ. See
Fig. 7
.
C. Wrap plastic tape around the splined part of the DOJ side of the axle shaft so
that DOJ boot/BJ boot are not damaged when they are removed.
Fig. 6: Removing Balls

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2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Rear - Endeavor

Fig. 7: Removing Double Offset Joint (DOJ) Cage

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Reassembly Service Points
CAUTION: DO NOT mix old, new, or different types of
grease, as a special grease is used in the joint.
CAUTION: In order to fill specified amount of air inside the
BJ boot, keep the bent angle of the axle shaft to 0
degrees during the operation.
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.

2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Rear - Endeavor

A. Wrap tape around the spline part of the shaft, then install BJ boot and DOJ
boot. Fill the inside of the BJ and BJ boot with specified grease. Tighten the
boot band.
B. Install the DOJ cage to the axle shaft and put it aside to BJ assembly side.
Align the mating mark to DOJ inner race with that of the shaft. See Fig. 8
. Tap
the inner race with even force to press-fit into the bump of the shaft with Brass
Bar (MB990939).
C. Fill the inside of the DOJ outer race and DOJ boot with the specified grease.
D. Position the DOJ outer race so that the distance between the boot bands as
shown. See Fig. 9
. Remove part of the DOJ boot from the DOJ outer race to
release the air pressure inside the boot.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease.

2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Rear - Endeavor

Fig. 8: Installing Double Offset Joint (DOJ) Cage & Inner Race

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Fig. 9: Installing Double Offset Joint (DOJ) Boot Bands (Small & Large)

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TORQUE SPECIFICATIONS For tor
que s
pecifications, see Fi
g. 2
.

2004 Mitsubishi Endeavor LS
2004 DRIVE AXLES Axle Shafts - Rear - Endeavor

2004 ELECTRICAL
Battery - Endeavor
BATTERY ON-VEHICLE SERVICE BATTERY CHECK
BATTERY VISUAL INSPECTION (1) 1. Ensure that the battery electrolyte level is between A and B shown in the
figure. Add if the level is lower than the specified range.
2. Use a hydrometer and temperature gauge to check the specific gravity of the
electrolyte.
Standard value:
1.220 - 1.290 [at 20°C (68°F)]
The specific gravity of electrolyte depends on its temperature. Use the formula
below to determine the proper value.
Conversion on centigrade
D20 =(t - 20) x 0.0007 + Dt
Conversion on Fahrenheit
D20 =(t - 68) x 0.0007 + Dt
D20 : Specific gravity as if electrolyte temperature is 20°C (68°F)
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. WASH HANDS
AFTER HANDLING.

2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor


2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor

Dt : Measured specific gravity
t: Measured temperature
Fig. 1: Battery Visual Inspection (1)

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BATTERY VISUAL INSPECTION (2) Make sure the ignition switch is in "LOCK" (OFF) position and all battery feed
accessories are OFF.
1. Disconnect the negative cable from the battery before disconnecting the
positive cable.
WARNING:Care should be taken in the event the battery

2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor

2. Remove the battery from the vehicle.
3. Inspect battery carrier for damage caused by loss of acid from the battery. If
acid damage is present, it is necessary to clean area with a solution of clean
warm water and baking soda. Scrub area with a stiff bristle brush. Wipe clean
with a cloth moistened with ammonia or baking soda in water.
4. Clean the battery, especially the top with same solutions as described in step 3.
5. Inspect the battery case and cover for cracks. If cracks are present, battery must
be replaced.
6. Clean the battery post with a suitable battery post cleaning tool.
7. Clean the inside surfaces of the terminal clamps with a suitable battery
terminal cleaning tool. Replace damaged or frayed cables and broken terminal
clamps.
8. Install the battery in the vehicle.
9. Connect the positive and negative cables to the battery in the order of mention.
10. Tighten the clamp nut securely. BATTERY CHARGING Battery electrolyte temperature may temporarily be allowed to rise to 55°C (131°F).
Increase of electrolyte temperature above 55°C (131°F) is harmful to the battery,
causing deformation of battery cell, decrease in life of battery, etc.
case is cracked or leaking to protect hands from
the electrolyte. A suitable pair of rubber gloves
(not the household type) should be worn when
removing battery by hand.
WARNING:When batteries are being charged, an explosive gas
forms beneath the cover of each cell. Do not smoke
near batteries on charge or which have recently
been charged. Do not break live circuits at the
terminals of the batteries on charge. A spark will
occur where the live circuit is broken. Keep all open
flames away from the battery.

2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor

CHARGE RATE If the test indicator is dark, the battery should be charged as outlined below. When
the dot appears or when maximum charge shown below is reached, charging should
be stopped. CHARGE RATE CHART Fig. 2: Charging Rate Chart

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BATTERY TEST BATTERY TESTING PROCEDURE
STEP 1. Check the battery cables.
Remove the negative cable, then the positive cable. Check for dirty or corroded
connections.
Q: Are the battery cables dirty or have corroded connections?
YES: Clean the battery cables. Then go to Step 2.
NO: Go to Step 2.
STEP 2. Check the battery post.
Check for loose battery post.
Q: Are the battery posts faulty?
YES: Replace the battery. Then go to Step 4 .
NO: Go to Step 3.

2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor

STEP 3. Check the battery case and cover.
1. Remove the hold-downs and shields.
2. Check for broken/cracked case or cover.
Q: Is the battery case or cover faulty?
YES: Replace the battery. Then go to Step 4.
NO: Go to Step 4.
STEP 4. Check the open circuit voltage.
1. Turn headlights on for 15 seconds.
2. Turn headlights off for two minutes to allow battery positive voltage to
stabilize.
3. Disconnect the battery cables.
4. Read open circuit voltage.
Q: Is open circuit voltage 12.4 volts or more?
YES: Go to Step 5.
NO: Charge the battery at 5 amps for 10.4 hours. Then re-test.
STEP 5. Check the load test.
1. Connect a load tester to the battery.
2. Load the battery at the recommended discharge rate (See LOAD TEST
RATE CHART
) for 15 seconds.
3. Read voltage after 15 seconds, then remove load.
4. Compare the measured value with the minimum voltage (See LOAD
TEST CHART
).
Q: Is the voltage higher than minimum voltage?
YES: The battery is normal.
NO: Replace the battery. Then go to Step 4 .
LOAD TEST RATE CHART
2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor

Fig. 3: Load Test Rate Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
LOAD TEST CHART Fig. 4: Load Test Chart

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2004 Mitsubishi Endeavor Limited 2004 ELECTRICAL Battery - Endeavor