2004 MITSUBISHI ENDEAVOR service

A. Wipe off grease from the spider assembly and the inside of the TJ case. Clean
the spider assembly if water or foreign material is present.
B. Wipe off grease from the shaft spline. When reusing the TJ boot or the BJ boot,
wrap plastic tape around the shaft spline to avoid damaging the boot. Reassembly Service Points (All-Wheel Drive) A. Wrap plastic tape around the shaft spline. Install small DOJ boot band and DOJ
boot. Then install the small TJ boot band and TJ boot.
B. Set the DOJ boot bands at the specified distance in order to adjust the amount
of air inside the DOJ boot. See Fig. 12
. Then tighten the small and large DOJ
boot bands.
C. Apply the specified grease furnished in the repair kit to the spider assembly
between the spider axle and the roller. Install the spider assembly to the shaft
from the direction of the spline chamfered side. See Fig. 13
.
D. After applying the specified grease to the TJ case, insert the axle shaft and
apply grease again.
E. Set the TJ boot bands at the specified distance in order to adjust the amount of
air inside the TJ boot. See Fig. 14
. Then tighten the small and large TJ boot
bands.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease. If the
spider assembly has been cleaned, take special
care to apply the specified grease.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease. If the
spider assembly has been cleaned, take special
care to apply the specified 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 DRIVE AXLES Axle Shafts - Front - Endeavor

Fig. 14: Installing Tripod Joint (TJ) Boot Bands (Small & Large)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disassembly Service Points (Front Wheel Drive) A. Wipe off grease from the spider assembly and then inside of the PTJ case.
Clean the spider assembly if water or foreign material is present.
B. Using Inner Shaft Puller (MB991248 or MB998801), remove the inner shaft
assembly from the PTJ case. See Fig. 15
. Using Side Bearing Puller
(MB990810), remove the center bearing bracket from the inner shaft. See Fig.
16 .
CAUTION: DO NOT disassemble the spider assembly

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

Q: Are the tires in normal condition?
YES: Go to Step 2.
NO: If out of balance, balance the tires as necessary. If excessively worn,
replace the tires as necessary and go to Step 5 .
STEP 2. Check the wheel alignment.
Refer to ON
-VEHICLE SERVICE
.
Q: Is the wheel alignment correct?
YES: Go to Step 3.
NO: Adjust it, then go to Step 5 .
STEP 3. Check the lower arm ball joint.
Q: Is the ball joint in good condition?
YES: Go to Step 4.
NO: Replace the lower arm assembly, then go to Step 5 .
STEP 4. Check the coil spring.
Q: Is the coil spring in good condition?
YES: Go to Step 5.
NO: Replace it, then go to Step 5.
STEP 5. Retest the system.
Q: Is the malfunction eliminated?
YES: The procedure is complete.
NO: Return to Step 1 .
INSPECTION PROCEDURE 2: Excessive Body Rolling DIAGNOSIS
STEP 1. Check for broken or deteriorated stabilizer bar
.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 4: Special Tools (2 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ON-VEHICLE SERVICE FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure wheel alignment with alignment equipment on a level surface. The front
sus
pension, steerin
g system, wheels, and tires should be serviced to normal
CAUTION: On vehicles with ASC, if the wheel alignment is
adjusted, always carry out steering wheel sensor
calibration (STEERING WHEEL SENSOR
CALIBRATION
). This is necessary because the
TCL/ASC-ECU should update the steering neutral
point.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 13: Disassembly And Assembly Of Strut Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:
MB991237: Spring Compressor MB991238: Arm Set MB991681: Wrench and Socket Set
DISASSEMBLY SERVICE POINT <> STRUT NUT REMOVAL
CAUTION:
Install the special tools evenly, and so that the
maximum length will be attained within the
installation range.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

2. Use a hexagon wrench and a pipe to secure the strut, and then remove the strut
nut using special tool MB991681.
Fig. 15: Removing Strut Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
DISASSEMBLY SERVICE POINT >>B<< STRUT ASSEMBLY DISPOSAL The gas must be discharged from the strut assembly before discarding it. Place the
assembly horizontally with its piston rod extended. Then drill a hole of
approximately 3 mm (0.1 inch) in diameter at the location shown in the illustration
and discharge the gas.
valve inside the strut to dropout.
WARNING:Wear goggles when drilling to protect your eyes
from flying metal debris.

2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 16: Drilling Location To Discharge Gas

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ASSEMBLY SERVICE POINT >>A<< SPRING LOWER PAD INSTALLATION Engage the three lugs of the spring lower pad into the holes on the front suspension
strut as shown in illustration.
2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor

Fig. 17: Aligning Spring Lower Pad

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
ASSEMBLY SERVICE POINT >>B<< STRUT INSULATOR INSTALLATION If the upper plate and lower plate of the strut insulator have been disassembled,
assemble them as shown in illustration.
2004 Mitsubishi Endeavor LS 2004 SUSPENSION Front - Endeavor