2004 MITSUBISHI ENDEAVOR oil level

10. If the change of the fluid level is 5 mm (0.2 inch) or more, the air has not been
completely bled from the system. The air bleeding procedure must be repeated.
Fig. 24: Identifying Fluid Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
OIL PUMP PRESSURE TEST Required Special Tools:
MB990662: Power Steering Oil Pressure Gauge MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side) MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side)
1. Disconnect the pressure hose from the oil pump, and then connect special tools
MB991548
, MB990662 and MB991549.

2004 Mitsubishi Endeavor LS
2004 STEERING Power Steering - 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

Fig. 4: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C (-10°F): SAE 90, 85W-90, 80W-90, From-34 to-23°C (-30
to-10°F
): SAE 80W
, 80W-90
, Below-34°C
(-30°F
): SAE 75W. Then
go to

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

Fig. 5: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C
(-10°F): SAE 90, 85W-90, 80W-90, Fro
m-34 to-23°C
(-30

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

Fig. 6: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Q: Is the gear oil level more than 8 mm (0.3 inch) below the bottom of the
filler plug hole?
YES: Check the oil leakage from differential carrier, and repair if
necessary. Then, refill Hypoid gear oil API classification GL-5 or higher;
Above-23°C
(-10°F
): SAE 90, 85W-90, 80W-90, Fro
m-34 to-23°C
(-30

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