2004 MITSUBISHI ENDEAVOR diagnosis

STEP 1. Check the oil pump body for damage.
Q: Is there damage?
YES: Replace the part. Then go to Step 3 .
NO: Go to Step 2.
STEP 2. Check the O-ring or oil seal for damage.
Q: Is there damage?
YES: Replace the part. Then go to Step 3.
NO: Go to Step 3.
STEP 3. Retest the system.
Check that no oil is leaking.
Q: Is there oil is leakage?
YES: Repeat from Step 1 .
NO: The procedure is complete.
INSPECTION PROCEDURE 14: OIL LEAKAGE FROM STEERING GEAR DIAGNOSIS
STEP 1. Check the steering gear housing for damage.
Q: Is there damage?
YES: Replace the part. Then go to Step 2.
NO: Go to Step 2.
STEP 2. Retest the system.
Check that no oil is leaking.
Q: Is there oil leakage?
YES: Re
peat from Ste
p 1 .

2004 Mitsubishi Endeavor LS
2004 STEERING Power Steering - Endeavor

Fig. 1: Identifying Rear Axle Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REAR AXLE DIAGNOSIS INTRODUCTION Noise from the drive shaft or differential may be caused by defects in the
components. TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you
will be sure that you have exhausted most of the possible ways to find a rear axle
fault.
1. Gather information from the customer.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart.
4. Verify malfunction is eliminated. SYMPTOM CHART Fig. 2: Identifying Symptom Chart

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: NOISE DURING WHEEL ROTATION {{DRIVE SHAFT}} DIAGNOSIS
STEP 1. Check the wheel bearing end play.
1. Remove the caliper assembly, and suspend the caliper assembly with a
wire and remove the brake disc.
2. Fit the dial gauge as shown in the diagram and move the hub in the axial
direction to measure the play.
Limit: 0.05 mm (0.002 inch)

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

STEP 2. Check the drive shaft for bending.
Q: Is the drive shaft bent?
YES: Replace the drive shaft assembly. Then go to Step 3.
NO: Go to Step 4 .
STEP 3. Check the drive shaft assembly for wear or damage.
Q: Is the drive shaft assembly worn or damaged?
YES: Replace the drive shaft assembly. Then go to Step 4.
NO: There is no action to be taken.
STEP 4. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Step 1.
INSPECTION PROCEDURE 2: CONSTANT NOISE {{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

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

DIAGNOSI
S
STEP 1. Check the drive pinion turning torque.
Q: Is the drive pinion turning torque correct?
YES: Go to Step 2.
NO: Adjust the turning torque. Then go to Step 3 .
STEP 2. Check the gear for damage.
Q: Is the gear damaged?
YES: Replace the gear. 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 5: BEARING NOISE WHILE DRIVING OR COASTING {{DIFFERENTIAL}} DIAGNOSIS
STEP 1. Check the drive pinion rear bearing for cracks or damage.
Q: Is the drive pinion rear bearing cracked or damaged?
YES: Replace the part. Then go to Step 2.
NO: Go to Step 2.
STEP 2. Retest the system.
Q: Is the abnormal noise eliminated?
YES: The procedure is complete.
NO: Start over at Ste
p 1.

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

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

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