cover MITSUBISHI ENDEAVOR 2004 Service Manual PDF

Fig. 46: Removing Steering Joint Cover

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSTALLATION SERVICE POINT >>A<< STEERING JOINT COVER INSTALLATION 1. Align the steering joint cover notch (arrow A) with the steering gear lug (arrow
B
), and then install the steerin
g joint cover to the steerin
g gear.

2004 Mitsubishi Endeavor LS
2004 STEERING Power Steering - Endeavor

Fig. 47: Aligning Steering Joint Cover Notch

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. From inside the vehicle, pull tab A and then tab B to secure the three clips to
the body panel.
NOTE: When securing the joint cover to the body panel, be
careful that the cover seal lip does not move
backwards.

2004 Mitsubishi Endeavor LS
2004 STEERING Power Steering - Endeavor

Fig. 48: Locating Tabs "A" & "B" To Secure Clips

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Check that it has been secured by pressing down the tip of the clips by your
finger. Also check that the steering gear-side joint cover is installed securely.
4. After installing the steering joint cover, check that the joint cover rubber is not
disengaged from the retainer. If there is any doubt, release the clips from the
body, engage the rubber again and reinstall to the body.
INSTALLATION SERVICE POINT >>B<< POWER STEERING GEAR BRACKET INSTALLATION Tighten the power steering gear bracket bolts in the alphabetical order shown in
illustration.
2004 Mitsubishi Endeavor LS
2004 STEERING Power Steering - Endeavor

4. If the measured value is below the standard value, the tie rod can be reused if it
swings smoothly without excessive play.
Fig. 53: Checking Tie Rod Swing Resistance

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
TIE ROD END BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger.
2. If the dust cover is cracked or damaged, replace the tie rod end. DISASSEMBLY AND ASSEMBLY
2004 Mitsubishi Endeavor LS
2004 STEERING Power Steering - Endeavor

to-10°F): SAE 80W, 80W-90, Below-34°C (-30°F): SAE 75W. Then go to
Step 3 .
NO: Go to Step 2.
STEP 2. Check for excessive gear backlash (Refer to DISASSEMBLY
).
Q: Is the gear backlash correct?
YES: Go to Step 3.
NO: Adjust the backlash. Then go to step 3.
STEP 3. Retest the system.
Q: Is the heat eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 8: OIL LEAKAGE {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the cover installation.
Q: Is the cover installed correctly?
YES: Go to Step 2.
NO: Repair. Then go to Step 4 .
STEP 2. Check the oil seal for wear or damage.
Q: Is the oil seal worn or damaged?
YES: Replace the seal. Then go to Step 4 .
NO: Go to Step 3.
STEP 3. Check the oil level.
Remove the filler
plug and check the
gear oil level.

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

Fig. 11: Identifying Special Tools (4 Of 4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ON-VEHICLE SERVICE REAR AXLE TOTAL BACKLASH CHECK 1. Park the vehicle on a flat, level surface.
2. Place the selector lever to the neutral position. Apply the parking brake and
jack up the vehicle.
3. Turn the propeller shaft clockwise as far as it will go. Make the mating marks
on the dust cover of the com
panion flan
ge and on the differential carrier.

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

2. Tighten the drive shaft nut to the specified torque with special tool MB990767.
Tightening torque: 236 +/- 19 N.m (174 +/- 14 ft-lb)
Fig. 33: Tightening Drive Shaft Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSPECTION
Check the drive shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the boots for deterioration, damage or cracking. Check the dust cover for damage or deterioration.
DISASSEMBLY AND ASSEMBLY
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

BALL JOINT DUST COVER INSPECTIONCheck the toe control arm assembly and the stabilizer bar link assembly ball joint
dust cover as follows.
1. Check dust covers for cracks or damage by pushing it with your finger.
2. If a dust cover is cracked or damaged, replace the toe control arm assembly or
the stabilizer bar link assembly. UPPER ARM ASSEMBLY REMOVAL AND INSTALLATION
NOTE: Cracks or damage to the dust cover may cause damage
to the ball joint.
CAUTION: *: Indicates parts which should be temporarily
tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Rear - Endeavor