Page 2932 of 3870
Q: Is the drive gear or differential case strained or damaged?
YES: Replace the part. Then go to Step 9 .
NO: Go to Step 8.
STEP 8. Check for foreign material.
Q: Is any foreign material found?
YES: Remove the foreign material and then inspect for damage. If
necessary, replace the part. Then go to Step 9.
NO: Go to Step 9.
STEP 9. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 3: GEAR NOISE WHILE DRIVING {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler
plug and check the
gear oil level.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2933 of 3870
Fig. 5: Checking Gear Oil Level
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C
(-10°F): SAE 90, 85W-90, 80W-90, Fro
m-34 to-23°C
(-30
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2936 of 3870
INSPECTION PROCEDURE 6: NOISE WHILE TURNING {{DIFFERENTIAL}}DIAGNOSIS
STEP 1. Check the side bearing for wear or damage.
Q: Is the side bearing worn or damaged?
YES: Replace the part. Then go to Step 3 .
NO: Go to step 2.
STEP 2. Check the side gear, pinion gear or pinion shaft for damage.
Q: Is the side gear, pinion gear or pinion shaft damaged?
YES: Replace the part. Then go to Step 3.
NO: Go to Step 3.
STEP 3. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 7: HEAT {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the oil level.
Remove the filler
plug and check the
gear oil level.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2937 of 3870
Fig. 6: Checking Gear Oil Level
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C
(-10°F
): SAE 90, 85W-90, 80W-90, Fro
m-34 to-23°C
(-30
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2938 of 3870
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
Page 2939 of 3870
Fig. 7: Checking Gear Oil Level
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Refill Hypoid gear oil API classification GL-5 or higher; Above-23°
C (-10°F): SAE 90, 85W-90, 80W-90, From-34 to-23°C (-30 to-10°F):
SAE 80W, 80W-90, Below-34°C
(-30°F
): SAE 75W. Then
go to Ste
p 4.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2946 of 3870
Fig. 13: Measuring Distance Between Mating Marks
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. If the backlash exceeds the limit value, remove the differential carrier assembly
and check the following.
Final drive gear backlash (Refer to DISASSEMBLY
).
Differential gear backlash (Refer to DISASSEMBLY
).
GEAR OIL LEVEL CHECK 1. Remove the filler plug.
2. Check that gear oil level is not 8 mm (0.3 inch) below the bottom of filler plug
hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2947 of 3870
Above-23°C (-10°F): SAE 90, 85W-90, 80W-90
From-34 to-23°C (-30 to-10°F): SAE 80W, 80W-90
Below-34°C (-30°F): SAE 75W
Fig. 14: Checking Gear Oil Level
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3.
Tighten the filler plug to the specified torque.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
