Mitsubishi Endeavor 2004-06

CV-Joints

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Overhaul



AWD Vehicles

NOTE
If the vehicle is equipped with ABS, do not strike the ABS rotors installed to the BJ outer race of the halfshaft against other parts when removing or installing the halfshaft. Otherwise the ABS rotors will be damaged.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft from the vehicle.
  4.  
  5. Remove the large and small TJ boot band.
  6.  
  7. Remove the TJ case.
  8.  
  9. Remove the circlips and snapring. Remove the spider assembly.
  10.  
  11. On the right side, remove the TJ boot.
  12.  
  13. On the left side, remove the DOJ large and small boot band, circlip, outer race, snapring, inner race, cage and ball assembly and DOJ boot.
  14.  
  15. On the right side, remove the large and small BJ boot bands. Remove the BJ boot.

    Click image to see an enlarged view

    Fig. Halfshaft and related components-AWD vehicles

  16.  

To install:

  1. Wrap tape around the shaft spline, and then install the DOJ small boot band. Install the large boot band.
  2.  
  3. Set the DOJ boot bands at the required distance -A- (3.23-3.47 inches) in order to adjust the amount of air inside the DOJ boot. Tighten the small and large boot bands securely.
    NOTE
    The halfshaft joint uses special grease. Do not mix old and new or different types of grease.

  4.  
  5. Apply the proper amount of grease 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.
  6.  
  7. Apply 4.1-4.7 ounces of grease to the TJ case. Insert the halfshaft and apply more grease.
    NOTE
    The total amount of grease should be divided in half for use, respectively, at the joint and inside the boot.

  8.  
  9. Set the TJ boot bands at the required distance -A- (3.42-3.66 inches) in order to adjust the amount of air inside the TJ boot. Tighten the small and large boot bands securely.
  10.  

FWD Vehicles

NOTE
If the vehicle is equipped with ABS, do not strike the ABS rotors installed to the BJ outer race of the halfshaft against other parts when removing or installing the halfshaft. Otherwise the ABS rotors will be damaged.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft from the vehicle.
  4.  
  5. Remove the large and small PTJ boot band.
  6.  
  7. On right side, use special tool MB991248 to remove the inner shaft assembly from the PTJ case.
  8.  
  9. Remove the PTJ case.
  10.  
  11. On right side, use special tool MB990810 to remove the center bearing bracket from the inner shaft. Remove the dust cover, bracket assembly, and inner and outer dust seal. Use tools MB990938 and MB990930 to remove the center bearing and center bearing bracket.
  12.  
  13. Remove the circlips and snapring. Remove the spider assembly. Remove the PTJ boot.
  14.  
  15. Remove the large and small BJ boot bands. Remove the BJ boot.

    Click image to see an enlarged view

    Fig. Halfshaft and related components-FWD vehicles

  16.  

To install:

  1. Wrap tape around the shaft spline, and then install the PTJ small boot band. Install the large boot band.
    NOTE
    The halfshaft joint uses special grease. Do not mix old and new or different types of grease.

  2.  
  3. Apply the proper amount of grease 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.
  4.  
  5. On the right side, use special tools MB990938 and MB990932 to press fit the center bearing into the center bearing bracket.
  6.  
  7. On the right side, apply 0.5-0.7 ounce of grease to the rear surface of the inner dust seal. Apply 0.3-0.4 ounce of grease to the rear surface of the outer dust seal.
  8.  
  9. Use special tools MB990890, MB990938 and MB990934 to press fit the dust seals into the center bearing bracket until they are flush with each other. Apply grease to the lip of each dust seal.

    Click image to see an enlarged view

    Fig. Inner and outer dust seal installation-FWD vehicles

  10.  
  11. Use special tool MB991172 to hold the center bearing inner race and press in the inner shaft. Apply grease to the inner shaft spline, and then press it into the PTJ case.
    NOTE
    When press fitting the inner shaft into the PTJ case, apply a thin coat of grease to the dust seal outer lip par and the outside edge of the PTJ axial part.

  12.  
  13. After applying 7.5-8.1 ounces of grease to the PTJ case, insert the halfshaft and apply more grease.
    NOTE
    The total amount of grease should be divided in half for use, respectively, at the joint and inside the boot.

  14.  
  15. Set the PTJ boot bands at the required distance -A- (3.23-3.47 inches) in order to adjust the amount of air inside the PTJ boot. Tighten the small and large boot bands securely.

    Click image to see an enlarged view

    Fig. Boot band measurement

  16.  

 
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