2004 MITSUBISHI ENDEAVOR oil

Fig. 7: 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: 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 Ste
p 4.

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

NO: Go to Step 4.
STEP 4. Retest the system.
Q: Is there oil leakage?
YES: Start over at Step 1.
NO: The procedure is complete.
SPECIAL TOOLS
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 13: Measuring Distance Between Mating Marks

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. If the backlash exceeds the limit value, remove the differential carrier assembly
and check the following.
Final drive gear backlash (Refer to DISASSEMBLY
).
Differential gear backlash (Refer to DISASSEMBLY
).
GEAR OIL LEVEL CHECK 1. Remove the filler plug.
2. Check that gear oil level is not 8 mm (0.3 inch) below the bottom of filler plug
hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

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
Fig. 14: Checking Gear Oil Level

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3.
Tighten the filler plug to the specified torque.

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

Tightening torque: 60 +/- 5 N.m (45 +
/-3 f
t-lb)
DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT Required Special Tools:
MB991380: Oil Seal Installer MB990938: Bar
1. Remove the drive shaft from the differential carrier (Refer to DRIVE SHAFT ASSEMBLY
).
2. Remove the differential carrier oil seal.

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

Fig. 16: Removing Differential Carrier Oil Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Use special tools MB990938 and MB991380 to press-fit a new oil seal.
4. Apply multi-purpose grease to the oil seal lip and drive shaft oil seal seating
area.
5. Replace the drive shaft circlip with a new one, and install the drive shaft to the
differential carrier
(Refer to DRIVE SHAFT ASSEMBLY
).

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

<> DRIVE SHAFT REMOVA
L
1. Use special tools MB990242, MB990244, MB991354 and MB990767 to push
out the drive shaft from the hub.
Fig. 30: Pusing Out Drive Shaft From Hub

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
Do not pull on the drive shaft; doing so will
damage the TJ; be sure to use special tools
MB991721, MB991833 and MB991961. When pulling the drive shaft out from the
differential carrier, be careful that the spline
part of the drive shaft does not damage the
oil seal.

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