boot MITSUBISHI MONTERO 1991 Workshop Manual
Page 811 of 1333
(not through) .......... 2 .. Suggest replacement of bellows
boot.
Bellows boot missing .... C .. Require replacement of bellows
boot.
Bellows boot
not sealing ............ A ... Require repair or replacement
of bellows boot.
Bellows boot torn ....... A .. Require replacement of bellows
boot.
Bellows boot twisted
(from toe adjustment) .. B ................. Require repair.
Fitting leaking ......... A .. Require repair or replacement.
Fitting missing ......... A . Require replacement of fitting.
Fitting threads
damaged ................ A ... Require repair or replacement
of part with damaged threads.
Fitting threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Flex coupler binding .... A ... Require repair or replacement
of coupler.
Flex coupler loose ...... A ... Require repair or replacement
of coupler.
Flex coupler
missing parts .......... A ... Require repair or replacement
of coupler.
Flex coupler
soft/spongy ............ A . Require replacement of coupler.
Flex coupler torn ....... A . Require replacement of coupler.
Fluid contaminated ...... B ........ (1) Require flushing and
refilling of the system.
Gasket leaking .......... A .. Require repair or replacement.
Hard steering on cold
start-up ............... 1 ........... ( 2) Suggest repair or
replacement.
Housing cracked,
affecting structural
integrity .............. B ............ Require replacement.
Housing leaking ......... A ............ Require replacement.
Inadequate power assist . A .......... ( 3) Further inspection
required.
Lash exceeds
manufacturer's
specifications ......... B .. Require repair or replacement.
Seal leaking ............ A .. Require repair or replacement.
Splines damaged ......... A .. Require repair or replacement.
Splines stripped
(splines missing) ...... A ............ Require replacement.
Steel line blocked ...... A ... Require repair or replacement
of line.
Steel line leaking ...... A ... Require repair or replacement
of line.
Steel line missing ...... C .... Require replacement of line.
Steel line restricted ... A ... Require repair or replacement
of line.
Steering coupler shield
cracked ................ 2 ............ Suggest replacement.
Steering coupler shield
missing ................ C ............ Require replacement.
Steering coupler shield
torn ................... 2 ............ Suggest replacement.
Threads damaged ......... A ... Require repair or replacement
of part with damaged threads.
Page 815 of 1333
specifications ......... B ............. Require replacement
of bearing.
Bearing binding ......... A ............. Require replacement
of bearing.
Bearing missing ......... C ............. Require replacement
of bearing.
Bearing seized .......... A ............. Require replacement
of bearing.
Bent .................... B ............ Require replacement.
Holes distorted ......... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Severely corroded,
affecting structural
integrity .............. A ............ Require replacement.
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SWAY BAR LINKS
SWAY BAR LINK INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
link.
Ball and socket has
looseness (perceptible
vertical movement) ..... 1 ........ ( 1) Suggest replacement.
Ball and socket has
looseness that is
excessive .............. B ..... ( 1)( 2) Require replacement.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Grease boot cracked ..... 2 ........ ( 3) Suggest replacement.
Grease boot missing ..... 2 ........ ( 4) Suggest replacement.
Grease boot torn ........ 2 ........ ( 5) Suggest replacement.
Missing ................. C ............ Require replacement.
Nut on stud loose ....... A ............. ( 6) Require repair.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Page 816 of 1333
Threads stripped (threads
missing) ............... A ........ (7) Require replacement.
( 1) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and
socket movement. Use only moderate hand pressure.
( 2) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural
integrity.
( 3) - Cracked grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 4) - Lack of grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 5) - Torn grease boot will allow contaminants to enter the
joint and will accelerate wear.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.
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SWAY BARS
SWAY BAR INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace sway bar.
Attaching hardware
corroded, affecting
structural integrity ... A .......... Require replacement of
corroded part, if available;
otherwise, replace sway bar.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace sway bar.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace sway bar.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace sway bar.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
sway bar.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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TIE ROD ENDS (INNER AND OUTER)
Page 817 of 1333
TIE ROD END (INNER AND OUTER) INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace tie rod end.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace tie rod end.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace tie rod end.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace tie rod end.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
tie rod end.
Adjusting sleeve bent ... B ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve clamps
out of position ........ B ................. Require repair.
Adjusting sleeve
corroded, affecting
structural integrity ... A ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve
missing ................ C ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve
seized ................. A ........... (1) Require repair or
replacement.
Adjusting sleeve
threads damaged ........ A ... Require repair or replacement
of sleeve or tie rod end.
Adjusting sleeve
threads stripped
(threads missing) ...... A ... Require replacement of sleeve
or tie rod end.
Binding ................. A .......... ( 2) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 3) Suggest replacement.
Grease boot missing ..... 2 ........ ( 4) Suggest replacement.
Grease boot torn ........ 2 ........ ( 5) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ......... ( 4) Suggest replacement
of seal.
Page 818 of 1333
Grease seal torn ........ 2 ......... (5) Suggest replacement
of seal.
Greaseable tie rod end
won't take grease ...... 2 ...... ( 6) Suggest replacement of
grease fitting.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 7) Suggest replacement.
Looseness exceeds
manufacturer's
specifications ......... B ............ Require replacement.
Looseness that is
excessive .............. B ..... ( 7)( 8) Require replacement.
Nut on stud loose ....... A ........... ( 9) Require repair or
replacement of nut.
Seized .................. A ............. Require replacement
Stud bent ............... B ....... ( 10) Require replacement.
Stud broken ............. A ....... ( 10) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ....... ( 10) Require replacement.
( 1) - Only required if toe needs to be adjusted.
( 2) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 3) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 5) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 6) - If greaseable tie rod end will not take grease after
replacing the grease fitting, suggest replacement of
tie rod end.
( 7) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 8) - Excessive looseness is defined as being significant enough
to affect vehicle handling or structural integrity.
( 9) - Check for bent stud or damaged taper hole.
( 10 ) - Check for damaged taper hole.
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TRACK BARS
TRACK BAR INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace track bar.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace track bar.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace track bar.
Attaching hardware
Page 819 of 1333
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace track bar.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
track bar.
Bent .................... B ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Grease boot cracked ..... 2 ........ (1) Suggest replacement.
Grease boot missing ..... 2 ........ ( 2) Suggest replacement.
Grease boot torn ........ 2 ........ ( 3) Suggest replacement.
Holes distorted ......... A ............ Require replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 4) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 4)( 5) Require replacement.
Nut on stud loose ....... A ........... ( 6) Require repair or
replacement of nut.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 2) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 4) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 5) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural integrity.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.
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TRAILING ARMS
TRAILING ARM INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace trailing arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
Page 1171 of 1333
REMOVAL
1) Disconnect negative battery cable. Remove front exhaust
pipe. On Montero, remove transfer case shift lever knob, dust boot and
retainer plate or console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
and remove. Disconnect all external solenoid and switch connections.
3) Disconnect speedometer cable and control cables at
transmission. Remove starter and bellhousing cover. Place reference
mark on torque converter and drive plate for reassembly reference.
Remove torque converter bolts.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
INSTALLATION
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Tighten mount bolts with weight of engine and transmission on mounts.
Ensure reference marks on drive shaft(s) and torque converter-to-drive\
plate align.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. Adjust all control cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Applications Ft. Lbs. (N.m)
FWD Models
Torque Converter-To-Drive Plate Bolt
Precis ....................................... 53-55 (72-76)
All Others ................................... 34-38 (46-52)
Transaxle-To-Engine Block Bolt
Mirage
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
12-mm Bolt ................................. 31-40 (42-54)
Eclipse & Galant
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
Precis
8-mm Bolt .................................. 22-25 (30-34)
10-mm Bolt ................................. 31-40 (42-54)
3000GT
Upper Coupling Bolts ............................. 54 (73)
Lower Coupling Bolts ............................. 65 (88)
Page 1192 of 1333
Defective diodes or stator See Bench Test in
ALTERNATOR article
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Battery Does Loose or worn drive belt Check alternator drive
Stay Charged belt tension and
condition. See
Belt Adjustment in
appropriate TUNE-UP
article in the
TUNE-UP section
Loose or corroded battery Check all charging
connections system connections
Loose alternator connections Check all charging
system connections
Defective alternator or See On-Vehicle Tests
battery and Bench Tests in
ALTERNATOR article
Add-on electrical accessories Install larger
exceeding alternator capacity alternator
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Battery Defective battery Check alternator
Overcharged- output and repair as
Uses Too Much necessary
Water
Defective alternator See On-Vehicle Test and
Bench Tests in
ALTERNATOR article
Excessive alternator voltage Check alternator output
and repair as necessary
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IGNITION SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
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START: Visually inspect Spark Plug Wires, Coil Wires,
Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.
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OK NOT OK
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* To test secondary ignition * Repair or replace
system, modify a Spark Plug damaged components
by attaching a ground wire as necessary
to the body of the plug and
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Page 1216 of 1333
or alcohol
Intermittent ECM ground Test ECM ground
connection for
resistance
Restricted air cleaner Replace air cleaner
Restricted exhaust system Test for exhaust
manifold back
pressure
Poor MAF sensor signal Check leakage
between sensor and
manifold
Poor VSS signal If tester for ALCL
hook-up is available
check that VSS
reading matches
speedometer
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Ping or Knock on Poor Knock sensor signal Test for shorted or
Acceleration open sensor or
circuit
Poor Baro sensor signal Test for shorted or
open sensor or
circuit
Improper ignition timing See VEHICLE EMISSION
CONTROL LABEL (where
applicable)
Check for engine Low coolant, loose
overheating problems belts or electric
cooling fan
inoperative
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NOTE: For additional electronic fuel injection trouble shooting
information, see the appropriate article in the ENGINE
PERFORMANCE section (not all vehicles have Computer Engine
Control articles). Information is provided there for
diagnosing fuel system problems on vehicles with electronic
fuel injection.
IGNITION SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
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START: Visually inspect Spark Plug Wires, Coil Wires,
Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.
Page 1239 of 1333
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE \
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Grease Leaks CV boot torn or cracked \
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Clicking Noise on Cornering Damaged outer CV \
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Clunk Noise on Acceleration Damaged inner CV \
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Vibration or Shudder Sticking, damaged or worn CV
on Acceleration Misalignment or spring height
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STEERING & SUSPENSION
MANUAL STEERING GEAR TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Rattle or Rack and pinion mounting Tighten all mounting
Chucking Noise bracket loose bolts
in Rack and
Pinion Lack of/or incorrect Correct as necessary
lubricant
Steering gear mounting Tighten all mounting
bolts loose bolts
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Excessive Play Front wheel bearing See FRONT SUSPENSION
improperly adjusted article
Loose or worn steering See STEERING LINKAGE
linkage article
Loose or worn steering See MANUAL STEERING
gear shift GEAR article
Steering arm loose on See MANUAL STEERING
gear shaft GEAR article
Steering gear housing Tighten all mounting
bolts loose bolts
Steering gear adjustment See MANUAL STEERING
too loose GEAR article
Steering arms loose on Tighten and check