2004 MITSUBISHI ENDEAVOR lock

Fig. 58: Driving Out Lock Pin With Punch

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<> SELF-LOCKING NUT REMOVAL Use special tool MB990850 to hold the companion flange, and then remove the
companion flange self-locking nut.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 59: Removing Companion Flange Self Locking Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
<> DRIVE PINION ASSEMBLY/COMPANION FLANGE REMOVAL 1. Make mating marks on the drive pinion and companion flange.
2. Use s
pecial tool MB990810 to
pull out the com
panion flan
ge.
CAUTION: The mating mark made on the companion flange
must not be on the coupling surface of the
companion flange and the front propeller shaft.

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

Fig. 74: Fitting Drive Pinion Rear Bearing Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>E< 1. Insert the drive pinion into the differential carrier, and then install the
following parts in sequence from the carrier rear side: drive pinion spacer,
drive pinion front shim, drive pinion front bearing inner race and companion
flange.
2. Tighten the companion flange self-locking nut to the specified torque while
holdin
g the com
panion flan
ge with s
pecial tool MB990850.
NOTE: Do not install the oil seal.

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

Tightening torque: 186 +/- 29 N.m (137 +/- 21 f
t-lb)
Fig. 75: Tightening Companion Flange Self Locking Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Use special tools MB990685 and MB990326 to measure the drive pinion
turning torque (without the drive pinion oil seal).
Standard value:
CAUTION: There should be no gear oil adhered to the
bearing.

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

Fig. 80: Inserting Drive Pinion Front Bearing Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Install the drive pinion assembly and companion flange with the mating marks
properly aligned. Tighten the companion flange self-locking nut to the
specified torque while holding the companion flange with special tool
MB990850.
Tightening torque: 186 +/- 29 N.m (137 +/- 21 ft-lb)

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

Fig. 81: Tightening Companion Flange Self Locking Nut

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Use special tools MB990685 and MB990326 to measure the drive pinion
turning torque (with drive pinion oil seal) to verify that the drive pinion turning
torque complies with the standard value.
Standard value:

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

Fig. 83: Turning Torque Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. If the turning torque is not within the standard value, check the tightening
torque of the companion flange self-locking nut, and the installation of the oil
seal.
>>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedure:
1. Assemble the side gears, side gear spacers, pinion gears, and pinion washers
into the differential case.
Fig. 84: Assembling Side Gears, Spacers, Pinion Gears & Washers Into
Differential Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

2. Temporarily install the pinion shaft.
3. Insert a wedge between the side gear and the pinion shaft to lock the side gear.
4. While locking the side gear with the wedge, measure the differential gear
backlash with a dial indicator on the pinion gear.
Measure by the same 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)
Fig. 85: Measuring Differential Gear Backlash With Dial Indicator

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
NOTE: Do not assemble the lock pin yet.

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