Page 2992 of 3870
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
Page 2993 of 3870
Use the wooden handle of a hammer to remove the differential case assembly,
differential side bearing spacers and differential side bearing outer races.
Fig. 55: Removing Differential Case Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
careful not to drop and damage the differential side
bearing spacers and differential side bearing outer
races.
NOTE: Keep the right and left side bearings and side bearing
spacers separate, so that they do not become mixed during
reassembly.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 2994 of 3870
<> DIFFERENTIAL SIDE BEARING INNER RACE REMOVALUse special tools MB990810 and MB990811 to pull out the side bearing inner
races.
Fig. 56: Pulling Out Side Bearing Inner Races
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<> DRIVE GEAR REMOVAL 1. Make the mating marks to the differential case and the drive gear.
2. Loosen the drive gear attaching bolts in a diagonal sequence to remove the
drive
gear.
NOTE: There are two notches provided (at the differential case
side) for the claw part of the special tools; use special tool
MB990810 at that position.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 3002 of 3870
Fig. 64: Exploded View Differential Carrier Assembly Components
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 3008 of 3870
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool MB990903.
Fig. 69: Applying Multipurpose Grease To Washer Of Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Install special tools MB990903 (MB990901) and MB991366(MB991378),
drive pinion front and rear bearing inner races to the differential carrier as
shown in the illustration.
CAUTION: There should be no gear oil adhered to the
bearing.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 3009 of 3870
3. Tighten the nut of special tool MB990903 a little at a time, while measuring
the turning torque of the drive pinion. Then confirm that the turning torque
(without the drive pinion oil seal) is at the standard value.
Standard value:
Fig. 70: Tightening Nut Of Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Clean thorou
ghly the side bearin
g seat of the differential carrier.
NOTE: Because the special tool cannot be turned one turn,
turn it several times within the range that it can be
turned; then, after fitting to the bearing, measure the
turning torque.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 3011 of 3870
Fig. 72: Bearing Division Turning Torque Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Place special tool MB991365 in the side bearing seat of the differential carrier,
and then select a drive pinion rear shim of a thickness which corresponds to the
gap between the special tools.
NOTE: When selecting the drive pinion rear shims, keep the
number of shims to a minimum.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
Page 3012 of 3870
Fig. 73: Placing Special Tool MB991365 In Side Bearing Seat Of Differential Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the
drive
pinion rear bearin
g inner race b
y usin
g special tool MB990728.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor
