2004 MITSUBISHI ENDEAVOR boot

Standard value (F): 2.4 - 2.8 mm (0.10 - 0.11 inch)
< If the crimping amount is larger than 2.8 mm (0.11 inch)>
Readjust the value of (W) in step 12 according to the following formula,
and then repeat the operation in step 14.
W = 5.8 mm (0.23 inch) - F
Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm (0.11 inch).
< If the crimping amount is smaller than 2.4 mm (0.10 inch)>
Remove the BJ boot band, readjust the value of (W) in step 12 according
to the following formula, and then repeat the operations in steps 13 and 14
using a new BJ boot band.
W = 5.8 mm (0.23 inch) - F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm (0.14 inch).

2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

Fig. 53: Identifying Crimping Amount Of Boot Band

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
16. Check that the boot band is not sticking out past the place where it has been
installed. If the boot band is sticking out, remove it and then repeat steps 13 to
15, using a new boot band.
SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS
2004 Mitsubishi Endeavor LS
2004 DRIVELINE/AXLES Front Axle Hub & Axle Shafts - Endeavor

A. Wipe off grease from the spider assembly and the inside of the TJ case. Clean
the spider assembly if water or foreign material is present.
B. Wipe off grease from the shaft spline. When reusing the TJ boot or the BJ boot,
wrap plastic tape around the shaft spline to avoid damaging the boot. Reassembly Service Points (All-Wheel Drive) A. Wrap plastic tape around the shaft spline. Install small DOJ boot band and DOJ
boot. Then install the small TJ boot band and TJ boot.
B. Set the DOJ boot bands at the specified distance in order to adjust the amount
of air inside the DOJ boot. See Fig. 12
. Then tighten the small and large DOJ
boot bands.
C. Apply the specified grease furnished in the repair kit to the spider assembly
between the spider axle and the roller. Install the spider assembly to the shaft
from the direction of the spline chamfered side. See Fig. 13
.
D. After applying the specified grease to the TJ case, insert the axle shaft and
apply grease again.
E. Set the TJ boot bands at the specified distance in order to adjust the amount of
air inside the TJ boot. See Fig. 14
. Then tighten the small and large TJ boot
bands.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease. If the
spider assembly has been cleaned, take special
care to apply the specified grease.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease. If the
spider assembly has been cleaned, take special
care to apply the specified grease.
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.

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

Fig. 12: Installing Boot Bands (Small & Large)

Courtes
y of MITSUBISHI MOTOR SALES OF AMERICA
.

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

Fig. 14: Installing Tripod Joint (TJ) Boot Bands (Small & Large)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disassembly Service Points (Front Wheel Drive) A. Wipe off grease from the spider assembly and then inside of the PTJ case.
Clean the spider assembly if water or foreign material is present.
B. Using Inner Shaft Puller (MB991248 or MB998801), remove the inner shaft
assembly from the PTJ case. See Fig. 15
. Using Side Bearing Puller
(MB990810), remove the center bearing bracket from the inner shaft. See Fig.
16 .
CAUTION: DO NOT disassemble the spider assembly

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

C. Using Bar (Snap-In Type) (MB990938) and Installer Adapter (MB990930),
remove the center bearing from the center bracket. See Fig. 17
.
D. Wipe off grease from the shaft spline. When reusing the PTJ boot, wrap plastic
around the shaft s
pline to avoid dama
ging the boot.

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

Fig. 17: Removing Center Bearing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Reassembly (Front Wheel Drive) A. Wrap plastic tape around the shaft spline, and then install the small and the PTJ
boot.
B. Apply the specified grease furnished in the repair kit to the spider assembly
between the s
pider and the roller. Install the s
pider assembl
y to the shaft from
CAUTION: The axle shaft uses special grease. DO NOT mix
old, new, or different types of grease. If the
spider assembly has been cleaned, take special
care to apply the specified grease.

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

the direction of the spline chamfered side. See Fig. 13
.
C. Using Bar (Snap-In Type) (MB990938) and Installer Adapter (MB990932),
press-fit the center bearing into the center bearing bracket. See Fig. 18
.
D. Apply the specified great (from the repair kit) to the rear surface of all dust
seals. Using Rear Suspension Bushing Base (MB990890), Bar (Snap-In type)
(MB990838), and Installer Adapter (MB990934), press the dust seals into the
center bearing bracket until they are flush with each other. See Fig. 19 . Apply
repair kit grease to the lip of each dust seal.
E. Using Inner Shaft Installer Base (MB991172), hold the center bearing inner
race, and then press-in the inner shaft. See Fig. 20
. Apply repair kit grease to
the inner shaft spline, then press-fit it into the PTJ case.
F. After applying the specified grease to the PTJ case, insert the axle shaft and
apply grease again.
G. Set the PTJ boot bands at the specified distance to adjust the amount of air
inside the PTJ joint, and then tighten the small and large PTJ boot bands. See
Fi
g. 12
. CAUTION: When applying grease, make sure that it does not
adhere to anything outside the lip.
NOTE: When press-fitting the inner shaft into the PTJ case,
apply a thin coat of repair kit grease to the dust seal
outer lip part and the outside edge of the PTJ axial part.
CAUTION: The axle shaft joint uses special grease. DO NOT
mix old, new, or different types of grease.
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.

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