2004 MITSUBISHI ENDEAVOR boot

Place a piece of wood, etc. against the caliper body as shown. Blow compressed air
through the brake hose connection hole to remove the piston boot and piston.
Fig. 62: Removing Piston Boot/Caliper Piston

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<< B>> PISTON SEAL REMOVAL
piston will pop out if a force of air is applied
suddenly.
CAUTION: Do not use a flat-tipped screwdriver or similar tool to

2004 Mitsubishi Endeavor LS
2004 BRAKES Basic Brake System - Endeavor

Fig. 5: Identifying Mating Marks On Differential Companion Flange And Propeller Shaft Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Insert a rag so as to avoid boot damage, and remove the propeller shaft
assembly in a straight and level manner.
CAUTION: Be careful not to bend the joint assembly when
removing the propeller shaft because this may
cause damage to the joint boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

If reusing the propeller shaft, align the mating marks of differential companion
flan
ge and
propeller shaft assembl
y to install.
Fig. 7: Locating Oil Seal Lips On Transfer Case

Courtes
y of MITSUBISHI MOTOR SALES OF AME
R
Remove oil and grease from the threads of the
mounting bolts and nuts before ti
ghtenin
g, or the
y
loosen. Be careful not to bend the
joint portion when rem
o
the propeller shaft, because this will damage the j
o
boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLE Propeller Shaft - Endeavor

2. Using special tool MB990767, tighten the drive shaft nut to the specified
torque 236 +/- 19 N.m (174 +/- 14 ft-lb).
Fig. 24: Tightening Drive Shaft Nut Using Special Tool MB990767

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISASSEMBLY AND ASSEMBLY < FWD>
damaged.
CAUTION:
For vehicles with ABS, be careful not to damage
the ABS rotor, which is attached to the BJ outer
race during disassembly and reassembly. Never disassemble the BJ assembl
y except when
replacing the BJ boot.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 25: Disassembling BJ Inner Shaft (FWD)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
NOTE:
PTJ: Pillow Tripod Joint BJ: Birfield Joint For BJ boot removal and installation, refer to BJ BOOT

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Required Special Tools:
MB991248 or MD998801: Inner Shaft Remover MB990810: Side Bearing Puller MB990930: Installer Adapter MB990932: Installer Adapter MB990934: Installer Adapter MB990938: Bar (snap-in type) MB990890: Rear Suspension Bushing Base MB991172: Inner Shaft Installer Base
LUBRICATION POINTS
(RESIN BOOT) REPLACEMENT
.

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 29: Removin
g Center Bearin
g From Center Bearin
g Bracket Usin
g Special
Tools

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<< D>> PTJ BOOT REMOVAL 1. Wipe off grease from the shaft spline.
2. When reusing the PTJ boot, wrap plastic tape around the shaft spline to avoid
damaging the boot. ASSEMBLY SERVICE POINTS >>A<< PTJ BOOT INSTALLATION Wrap plastic tape around the shaft spline, and then install the PTJ boot band (small)
and PTJ boot.
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 35: Pressing Inner Shaft Into PTJ Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>F<< PTJ CASE INSTALLATION After applying the specified grease to the PTJ case, insert the drive shaft and apply
grease again.
Specified grease: Repair kit grease
Amount to use: 220 +/- 10 g (7.8 +/- 0.3 ounces)
CAUTION: The drive shaft joint use special grease. Do not mix
old and new or different types of grease.
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 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor