Page 2985 of 3870
Fig. 48: Removing Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Hold special tools MB990909 and MB991116 in a vise, and install the
differential carrier assembly to the special tool.
FINAL DRIVE GEAR BACKLASH 1. With the drive pinion locked in place, use a dial gauge to measure the drive
gear backlash in four or more places on the drive gear.
Standard value: 0.11 - 0.16 mm (0.004 - 0.006 inch)
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2986 of 3870
Fig. 49: Measuring Final Drive Gear Backlash
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. If the backlash is not within the standard value, adjust the final drive gear
backlash (Refer to ASSEMBLY
).
3. After the adjustment, inspect the final drive gear tooth contact.
DRIVE GEAR RUNOUT
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2987 of 3870
1. Measure the drive gear runout at the shoulder on the reverse side of the drive
gear.
Limit: 0.05 mm (0.002 inch)
Fig. 50: Measuring Drive Gear Runout
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. When runout exceeds the limit value, check for forei
gn material between drive
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2988 of 3870
gear rear side and differential case, or for loose drive gear installation bolts.
3. When step (2) gives normal results, reposition the drive gear and differential
case and remeasure.
4. If adjustment is impossible, replace the differential case, or replace the drive
gear and pinion as a set.
DIFFERENTIAL GEAR BACKLASH 1. Insert a wedge between the side gear and the pinion shaft to lock the side gear.
2. While locking the side gear with the wedge, measure the differential gear
backlash with a dial indicator on the pinion gear.
Use the measurement procedure for the other pinion gear.
Standard value: 0,01 - 0.250 mm (0.0004 - 0.0098 inch)
Limit: 0.2 mm (0.01 inch)
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2989 of 3870
Fig. 51: Measuring Differential Gear Backlas
h
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. If the backlash exceeds the limit value, adjust it by replacing the side gear
spacers.
4. If adjustment is not possible, replace the side gears and pinion gears as a set.
FINAL DRIVE GEAR TOOTH CONTACT Check the tooth contact of drive gear by following the steps below.
1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear
teeth.
Fig. 52: Applying Thin Uniform Coat Of Machine Blue To Both Surfaces
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2990 of 3870
Of The Drive Gear Teet
h
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Insert special tool MB990939 between the differential carrier and the
differential case, and then rotate the companion flange by hand (once in the
normal direction, and then once in the reverse direction) while applying a load
to the drive gear so that the revolution torque [approximately 2.5 - 3.0 N.m
(22.1 - 26.6 i
n-lb)] is applied to the drive pinion.
CAUTION: If the drive gear is rotated too much, the tooth
contact pattern will become unclear and difficult
to check.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2991 of 3870
Fig. 53: Rotating Companion Flange
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Check the tooth contact condition of the drive
gear and drive
pinion.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
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Fig. 54: Tooth Contact Pattern Specification Chart
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<> DIFFERENTIAL CASE ASSEMBLY/DIFFERENTIAL SIDE BEARING SPACER/DIFFERENTIAL SIDE BEARING
OUTER RACE REMOVAL NOTE: Check the tooth contact pattern to confirm that the
adjustments of the pinion height and backlash have been
done properly. Continue to adjust the pinion height and
backlash until the tooth contact pattern resembles the
standard pattern. If, even after adjustments have been
made, the correct tooth contact pattern cannot be obtained,
it means that the drive gear and the drive pinion have
become worn beyond the allowable limit. Replace the gear
set.
CAUTION: When taking out the differential case assembly, be
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor