2004 MITSUBISHI ENDEAVOR differential

Fig. 43: Removing/Installing Differential Carrier Assembly Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
REMOVAL SERVICE POINTS <> PROPELLER SHAFT DISCONNECTION 1. Make mating marks on the differential companion flange and the propeller
shaft assembly.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 44: Mating Marks On Differential Companion Flange

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Suspend the removed propeller shaft from the body with a wire to prevent
bending.
INSTALLATION SERVICE POINTS >>A<< PROPELLER SHAFT INSTALLATION Align the mating marks of differential companion flange and propeller shaft
assembly. DIFFERENTIAL MOUNT BRACKET BUSHING REPLACEMENT Required Special Tools:
MB991448: Bush Remover and Installer Base

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

MB991522(MB991526): Torsion Bar Bushing Remover and Installer (Installer
Guide)
1. Use special tool MB991448 to remove the bushing.
Fig. 45: Removing Bushing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Use special tool MB991526 to press-fit the bushing until the bushing outer
case end face is flush with the differential mount
bracket.

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

Fig. 47: Exploded View Differential Carrier Assembly Components

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Required Special Tools:
MB
990909:
Wo
rkin
g Base


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

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

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

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

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