2004 MITSUBISHI ENDEAVOR differential

Fig. 190: Installing >>B<< Taper Roller Bearing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>C<< SPACER, SIDE GEAR, WASHER, PINION AND PINION SHAFT, PINION SHAFT HOLDER, LOCK PIN, FRONT
OUTPUT SHAFT, SNAP RING, CENTER DIFFERENTIAL FLANGE, INSTALLATION 1. Mount a spacer on the back surface of the side gear, and then install the side
gear in the differential case.
2. Place the washers on the back of the pinions, and simultaneously mesh the four
pieces with the side gears. Place them into position while rotating them. Then,
install the
pinion shaft holder.
NOTE: When a new side gear is to be installed, use a medium
thickness spacer [0.93 to 1.00 mm (0.0366 to 0.0395
inch)].

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 191: Installing Side Gear In Differential Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Insert the pinion shaft.
4. Install the lock pin so that it will be oriented in the direction shown.
5. Install the front output shaft on the side gear, and install the snap ring.
6. Mount a spacer on the back surface of the side gear, and then install the side
gear in the differential case.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 192: Inserting Pinion Shaft

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Install the center differential flange by aligning the matching marks, and
temporarily tighten the four machine screws.
8. Measure the backlash between the side gear and pinion.
Standard value:
0.025 - 0.150 mm (0.0010 - 0.0059 inch)
9. If the backlash is out of the standard value
, select a s
pacer and r
e-measure the
NOTE: When a new side gear is to be installed, use a medium
thickness spacer [0.93 to 1.00 mm (0.0366 to 0.0395
inch)]

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

backlash.
Fig. 193: Measuring Backlash Between Side Gear And Pinion

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>D<< DIFFERENTIAL DRIVE GEAR INSTALLATION Apply ATF to the bolts, and then tighten the bolts to the specified torque in the
sequence shown.
NOTE: Adjust until the backlash on both sides are equal.
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Tightening torque: 135 +/- 5 N.m (100 +/- 4 f
t-lb)
Fig. 194: Identifying Differential Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
VALVE BODY DISASSEMBLY AND ASSEMBLY
2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Spacer (For adjustment of output shaft preload)
Fig. 222: Spacer Identification Symbol Table (For Adjustment Of Output Shaft Preload)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Spacer (For Adjustment Of Differential case preload)
Fig. 223: Spacer Identification Symbol Table (For adjustment of differential
case preload)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Spacer (For Adjustment Of Backlash Between Differential Side Gear And
Pinion) < F4A5A >

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

Fig. 224: Spacer Identification Symbol Table (For Adjustment Of Backlash Between Differential Side Gear And Pinion)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Spacer (For adjustment of backlash between center differential side gear and
pinion) < W4A5A >
Fig. 225: Spacer Identification Symbol Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SEALANTS Fig. 226: Item Specified Sealants Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

2004 Mitsubishi Endeavor XLS
2004 TRANSMISSION Automatic Transaxle Overhaul - Endeavor

B. Using Puller Shaft (MB990242), Puller Bar (MB990244), Puller Body
(MB991354), and End Yoke Holder (MB990767), push out the axle shaft from
the hub. Using Sliding Hammer (MB991721), Drive Shaft Puller (MB991833),
and Adapter (MB991961), remove the axle shaft from the differential carrier.
damage the TJ. Be sure to use Sliding Hammer
(MB991721), Drive Shaft Puller (MB991833), and
Adapter (MB991961) to remove the axle shaft.
CAUTION: DO NOT apply pressure (by vehicle weight to the
wheel bearing when the axle shaft is removed. If,
however, vehicle weight must be applied to the
bearing by using Spacer (MB991000 or
MB990998) and Front Hub Remover and Installer
(MB991017). See Fig. 3
.

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