actuator MITSUBISHI MONTERO 1991 User Guide

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* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS

refer to the component listing in this document.








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TRANSFER CASE ASSEMBLIES
TRANSFER CASE ASSEMBLY INSPECTION








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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the transfer case
differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.









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DRIVE TRAIN/COMPONENTS
The conditions listed for the components included in this
section assume that the problem has been isolated to the specific
component through proper testing.
ACTUATORS (ELECTRICAL)
ACTUATOR (ELECTRICAL) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 1 ........... ( 1) Suggest repair or

replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 1 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out
of OEM specification.









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ACTUATORS (VACUUM)
ACTUATOR (VACUUM) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking (vacuum) ........ A .. Require repair or replacement.
Linkage bent, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage bent, not
affecting performance .. 2 ... Suggest repair or replacement
of linkage.
Linkage binding, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage binding, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage broken A Require repair or replacement
of linkage.
Linkage loose, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage loose, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.

FLYWHEEL INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Cracked (other than
mounting area) ......... A ...... (1) Require resurfacing or
replacement.
Cracks in mounting area . B ............ Require replacement.
Hard spots .............. B .. Require repair or replacement.
Ring gear broken ........ A ..... Require replacement of ring
gear.
Ring gear teeth worn,
affecting performance .. A ..... Require replacement of ring
gear.
Runout exceeds
specifications ......... B .. Require repair or replacement.
Scored .................. B .. Require repair or replacement.
Surface cracks after
resurfacing to
manufacturer's minimum
specifications ......... B ............ Require replacement.
Wear exceeds
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Some manufacturers allow slight surface cracking in the
friction surface.









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FORCE MOTORS
See ACTUATORS (ELECTRICAL) .
GUIDES
See DOWEL PINS, GUIDES AND PILOT HOLES .
HALF SHAFTS
See DRIVE SHAFTS AND HALF SHAFTS .
HOSES, LINES AND TUBES
HOSE, LINE AND TUBE INSPECTION








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Condition Code Procedure

vent may force fluid past the seal.








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SEALS (METAL-CLAD)
See SEALS.
SELECTOR INTERLOCK SYSTEMS
See
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS) .
SERVOS
See ACTUATORS (VACUUM) .
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
See:
ACTUATORS (ELECTRICAL)
CABLES
LINKAGES (EXTERNAL)
SWITCHES
SENSORS
SENSOR INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking
(vacuum/fluid/air) ..... A ............ Require replacement.
Out of adjustment ....... B .......... ( 3) Further inspection
required.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting

performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
specification.
( 3) - Follow OEM recommended adjustment procedures. Repair
or replace if out of specification.









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SIDE COVERS
See TRANSMISSION PANS .
SLIP YOKES
See YOKES AND SLIP YOKES .
SOLENOIDS
See:
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEED SENSOR (ELECTRONIC WHEEL AND VEHICLE) INSPECTION








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Condition Code Procedure
Air gap incorrect ....... B ....... ( 1) Require adjustment or
replacement.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 3) Require repair or
replacement.
Inoperative ............. B ........... ( 4) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of

Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bearing cap distorted ... B ............ Require replacement.
Binding ................. A ............ Require replacement.
Cross (trunion) worn,
affecting performance .. A ............ Require replacement.
Double cardon centering
ball damaged ........... A ............ Require replacement.
Double cardon centering
ball worn, affecting
performance ............ A ............ Require replacement.
Double cardon centering
spring broken .......... A ............ Require replacement.
Double cardon centering
spring missing ......... C ............ Require replacement.
Double cardon centering
spring weak ............ A ............ Require replacement.
End cap seal cracked .... 2 ............ Suggest replacement.
End cap seal missing .... C .... Require replacement of seal.
Grease fitting broken ... A ...... (1) Require replacement of
grease fitting.
Grease fitting missing .. C ...... ( 2) Require replacement of
grease fitting.
Rust-colored powder around
end cap seals .......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - A broken grease fitting does not require replacement
of the U-Joint.
( 2) - A missing grease fitting does not require replacement
of the U-Joint.









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VACUUM CONTROLS
See ACTUATORS (VACUUM) .
VACUUM HOSES
See HOSES, LINES AND TUBES .
VACUUM MOTORS
See ACTUATORS (VACUUM) .
VACUUM-OPERATED SWITCHES
See SWITCHES.
VEHICLE SPEED SENSORS
See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .
VENTS

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* E LE C TR IC AL S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM)
AIR BAGS
ALTERNATORS AND GENERATORS
AMPLIFIERS
ANTENNAS
BATTERIES
BATTERY CABLES
BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS
CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES
CIRCUIT BREAKERS
CLUTCH SWITCHES
CONNECTORS
CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES
CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS
DEFROSTERS
DELAYS
DIMMERS
ELECTRIC HEATERS
EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GAUGES
GENERATORS
GROUND CABLES AND STRAPS
GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS)
HORNS AND SIRENS

When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
ELECTRICAL SYSTEMS
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER
VEHICLE OPERATION
NOTE: When working on electrical systems, if a potentially
hazardous condition is observed, require repair or
replacement of affected components prior to performing
further work.
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTOR (SOLENOIDS) (ELECTRIC) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.

Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Linkage bent, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage bent, not
affecting performance .. 2 ... Suggest repair or replacement
of linkage.
Linkage binding, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage binding, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage broken .......... A ... Require repair or replacement
of linkage.
Linkage loose, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage loose, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage missing ......... C ............ Require replacement.
Linkage noisy ........... 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 1 ........... ( 1) Suggest repair or
replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 1 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of OEM
specification.









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ACTUATOR MOTORS (VACUUM)
ACTUATOR MOTOR (VACUUM) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of