2004 MITSUBISHI ENDEAVOR check oil

Fig. 83: Turning Torque Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. If the turning torque is not within the standard value, check the tightening
torque of the companion flange self-locking nut, and the installation of the oil
seal.
>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear spacers, pinion gears, and pinion washers
into the differential case.
Fig. 84: Assembling Side Gears, Spacers, Pinion Gears & Washers Into
Differential Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig. 20: Removing & Installing Shock Absorber

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
INSPECTION
Check the rubber parts for cracks and wear. Check the shock absorber for malfunctions, oil leakage, or abnormal noise.
DISASSEMBLY AND ASSEMBLY
2004 Mitsubishi Endeavor LS 2004 SUSPENSION Rear - Endeavor

2004 STARTING & CHARGING SYSTEMS
Starters - Endeavor
DESCRIPTION & OPERATION If the ignition switch is turned to START position, current flows in the coil
provided inside magnetic switch, attracting the plunger. When plunger is attracted,
the lever connected to plunger is actuated to engage starter clutch. On the other
hand, attracting plunger will turn on magnetic switch, allowing "B" terminal and
"M" terminal to conduct. Thus, current flows to engage starter motor. When
ignition switch is returned to ON position after starting engine, starter clutch is
disengaged from ring gear.
An overrunning clutch is provided between pinion and armature shaft to prevent
damage to starter.
When the ignition switch is switched to the START position while the selector leve
r
is at the "P" or "N" range, the contact (magnetic switch) of the starter is switched
ON and the starter motor is activated.
ADJUSTMENT PINION GAP 1. Disconnect the field coil wire from the "M" terminal of magnetic switch.
2. Connect a 12V battery between "S" terminal and "M" terminal. See Fig. 1
.
3. Set switch to ON and pinion will move out.
4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. See
Fig. 2
.
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s)
between the ma
gnetic switch and front bracket. CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor


2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 2: Measuring Pinion Gap

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA
TROUBLE SHOOTING STARTER MOTOR DOES NOT OPERATE
Check the starter (coil). Check for poor contact at the battery terminals and starter. Check the transmission ran
ge switch.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

STARTER MOTOR DOES NOT STOPCheck the magnetic switch. ON-VEHICLE TESTING STARTER MOTOR DOES NOT OPERATE 1. Is the battery in good condition? If Yes, go to the next step. If No, then charge
or replace battery.
2. Disconnect the starter motor "S" (solenoid) terminal connector. Using a jumper
wire, apply battery positive voltage to starter motor "S" (solenoid) terminal.
Does starter motor operate normally? If Yes, then check ignition switch,
transmission range switch and the line between the battery and starter motor
"S" (solenoid) terminal. If No, then go to the next step.
3. Check if the cable between starter "B" (battery) terminal and battery positive
terminal for connection and continuity. Is the starter cable in good condition? I
f
Yes, then go to the next step. If No, then repair or replace the cable.
4. Check the connection and continuity of the cable between starter motor body
and the negative battery terminal. Is the ground line in good condition? If Yes,
then go to the next step. If No, then repair or replace cable.
5. Is the starter motor in good condition? If Yes, problem is excessive rotational
resistance of the engine. If No, then replace the starter motor.
BENCH TESTING MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from "M" terminal of the magnetic switch. See Fig.
3 . WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
CAUTION: To prevent coil from burning, DO NOT apply voltage
to starter assembly for more than 10 seconds.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 7: Checking Overrunning Clutc
h
Courtesy of KIA MOTORS AMERICA, INC.
FRONT & REAR BRACKET BUSHING CHECK Inspect the bushing for wear or burrs. If the bushing is worn or burred, replace the
front bracket assembly or rear bracket assembly. ARMATURE CHECK 1. Check that the armature coil is not grounded.
2. Place armature in a growler. See Fig. 8
.
3. Hold a thin steel blade parallel and just above while rotating the armature
slowly in the growler. A shorted armature will cause a blade to vibrate and
attract to the core. Replace the shorted armature.
4. Check the insulation between the armature coil cores and the commutator
segments. They are normal if there is no continuity. See Fig. 9
.
5. Check for continuity between the segments. The condition is normal if there is
continuit
y. See Fig. 10
.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 9: Checking Armature Coil Ground Test

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor

Fig. 10: Checking Armature Coil Open Circuit

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REMOVAL & INSTALLATION
OVERHAUL NOTE: Information is not available from manufacturer.
NOTE: To assist in overhaul use illustration. See Fig. 11
.

2004 Mitsubishi Endeavor Limited
2004 STARTING & CHARGING SYSTEMS Starters - Endeavor