2004 MITSUBISHI ENDEAVOR differential

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

Fig. 79: Identifying Colour Table

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Remove the companion flange and drive pinion again. Then insert the drive
pinion front bearing inner race into the differential carrier. Use special tool
MB990727 to pres
s-fit the drive pinion oil seal.

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

5. If the backlash exceeds the limit value, adjust it by replacing the side gear
spacers.
6. If adjustment is not possible, replace the side gears and pinion gears as a set.
7. Check that the backlash is within the limit value and that the differential gear
turns smoothly. >>G<< LOCK PIN INSTALLATION 1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and
drive in the lock pin.
2. Stake the lock pin with a punch on both sides.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 88: Applying Stud Locking Or Equivalent To Threaded Holes Of Drive Gear

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Install the drive gear onto the differential case with the mating marks properly
aligned. Tighten the drive gear attaching bolts to the specified torque in a
diagonal sequence.
Tightening torque: 84 +/- 4 N.m (62 +/- 3 ft-lb)
>>I<< DIFFERENTIAL SIDE BEARING INNER RACE INSTALLATION Use special tool MB990728 to press-fit the differential side bearing inner races into
the differential case.
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor

Fig. 89: Installing Differential Side Bearing Inner Race

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
>>J<< DIFFERENTIAL SIDE BEARING NUT INSTALLATION/SNAP RING & FINAL DRIVE GEAR BACKLASH
ADJUSTMENT Adjust the final drive gear backlash by the following procedure:
1. Using special tools MB991367 and MB991385, temporarily tighten the side
bearin
g nut to
just before
preloadin
g of the side bearin
g.

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

Fig. 95: Measuring Drive Gear Runout

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. If drive gear runout exceeds the limit, remove the differential case and then the
drive gears, moving them to different positions and reinstall them.
9. If adjustment is not possible, replace the differential case or drive gear and
drive pinion as a set.
SPECIFICATIONS
2004 Mitsubishi Endeavor LS
2004 SUSPENSION Rear Axle < AWD > - Endeavor