torque MITSUBISHI MONTERO 1991 Manual PDF

1) Install input gear and front output shaft oil seals into
transfer case housing. Pack grease between lips of seals and press
seal circumference uniformly.
2) Install input gear assembly in transfer case. See Figs. 3
and 6. Input gear assembly snap ring is available in selective
thicknesses. Use thickest snap ring that will fit into input shaft
groove. Allowed snap ring clearance is 0-.0024" (0-.060 mm).
3) Insert needle bearing onto rear output shaft assembly.
Install high-low synchronizer sleeve and shift fork. Install 2WD-4WD
shift fork. Engage chain securely on front and rear output shaft
sprockets. Assemble 2WD-4WD synchronizer sleeve with 2WD-4WD shift
fork. Install assembly over 2WD-4WD shift rail. Install front and rear
output shafts with chain as an assembly.
4) Install 2WD-4WD shift lug, distance piece, 2WD-4WD shift
rail and spring pin. Ensure slit in spring pin is in line with 2WD-4WD
shift rail. Install 2 spring retainers with spring on 2WD-4WD shift
rail. Install snap ring to end of 2WD-4WD shift rail. See Fig. 3.
5) Insert 2 needle bearings and spacer into countergear.
Install one thrust washer at each end of countergear. Ensure tab on
thrust washers fits into groove of transfer case. Install countergear
shaft assembly with "O" ring.
6) Install side cover and gasket. Install oil guide. Apply
sealant to both sides of gasket and install gasket and chain cover.
Ensure oil guide end fits into chain cover opening. Fit snap ring into
groove of rear bearing on rear output shaft. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
7) Install interlock plunger. Shift 2WD-4WD shift rail to 4WD
position. Install high-low shift rail through high-low shift fork in
case. Install 2 poppet balls and springs. Install seal plugs. When
installing poppet springs, smaller end must be toward ball.
8) On models with pulse generator, install pulse rotor, wave
spring and spacer. Measure protrusion "A" of front output shaft rear
bearing and recess "B" of cover and calculate clearance. See Fig. 9.
If clearance is greater than .079" (2.0 mm), select and install spacer\
to bring clearance within specification. If clearance is less than .
079" (2.0 mm), use wave spring alone. Apply sealant to both sides of
gasket and install gasket and cover. Install pulse generator (if
equipped).
9) On all models, align high-low shift fork and shift rail
spring holes and drive in roll pin with punch. Roll pin should be
installed with slit on center line of shift rail. Install wave spring
on rear of rear output shaft bearing. Apply sealant to both sides of
rear cover gasket. Install gasket and cover.
10) Check output shaft end play. Measure protrusion "A" of
rear output shaft rear bearing and recess "B" of cover and calculate
clearance. Ensure end play is 0-.004" (0-.10 mm). Apply sealant to
both sides of gasket and install gasket and cover. See Fig. 9.
11) Install speedometer sleeve assembly in rear cover. Align
match mark on speedometer sleeve assembly in rear cover. See Fig. 10.
Align match mark on speedometer sleeve with mark on case according to
number of teeth on speedometer driven gear. Install speedometer driven
gear sleeve clamp and tighten bolt to specification. Install both 4WD
indicator light switches with steel balls. See TORQUE SPECIFICATIONS.

4WD shift rail snap ring.
6) Assemble front output shaft assembly, chain and 2WD-4WD
synchronizer assembly. Align match marks made during disassembly. Link
chain tightly onto 2WD-4WD synchronizer and front output shaft
sprockets. Install both sprockets and chain to transfer case at same
time, while keeping them as far apart as possible.
7) Install center differential case assembly, rear output
shaft assembly needle bearings and rear output shaft assembly. Install
interlock plunger so it does not interfere with 2WD-4WD shift rail.
Evenly apply sealant to chain cover and install chain cover.
8) Install high-low shift rail through high-low shift rail
hole into shift fork. Align spring pin holes in high-low shift rail
and shift fork. Tap in spring pin so slit is facing shift rail shaft
center. Install and tighten high-low shift rail plug to specification.
See TORQUE SPECIFICATIONS .
9) Before installing front output shaft cover, measure
protrusion "A" of front output shaft rear bearing and recess "B" of
cover and calculate clearance. See Fig. 11. If clearance is greater
than .079" (2.00 mm), select and install spacer to bring clearance
within specification. If clearance is less than .079" (2.00 mm), use
wave spring alone. Apply sealant to both sides of gasket and install
gasket and cover. Apply Locking Adhesive (3M 4170 Stud Lock) to bolts
and tighten to specification. See TORQUE SPECIFICATIONS.
Fig. 11: Measuring Rear Output Shaft Bearing Clearance (Montero)
Courtesy of Mitsubishi Motor Sales of America.
10) Install rear output shaft ball bearing snap ring. Measure
clearance between chain cover and snap ring. Add .0008-.0039" (.02-.10

mm) to clearance measured and install spacer of similar thickness.
Install rear output shaft oil seal (apply grease to lip of seal).
Install rear cover oil seal (apply grease to lip of seal).
11) Before installing rear cover, snap ring and spacer
thicknesses must be determined. Measure protrusion of rear output
shaft bearing. Measure inset of both stages of cover. Subtract inset
recess from rear bearing protrusion. Select a snap ring which adjusts
difference between inset recess and rear bearing protrusion, and
spacer thickness to 0-.004" (0-0.10 mm). Evenly apply sealant to rear
cover and install cover. Tighten bolts to specification. Refer to the
TORQUE SPECIFICATIONS table.
12) Install speedometer gear, ensuring mating marks match
according to number of gear teeth. Install speedometer gear sleeve
clamp and tighten bolt to specification. See Fig. 10.
13) Apply sealant to poppet plug threads. Install poppet
steel balls, springs and poppet plugs and tighten to specification.
Install detection switches, steel balls and gaskets. See Fig. 12.
Install dynamic damper and tighten bolts to specification.
Fig. 12: Installation Of Detection Switches (Montero)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Adapter-To-Transfer Bearing Retainer ......... (1) 14 (19)
Case Nuts & Bolts .......................... 22-31 (30-42)
Center Differential Case Bolts ................... 48 (65)
Chain Cover Bolt ........................... 22-31 (30-42)
Detection Switch ............................. ( 1) 27 (36)
Drain Plug ................................. 22-26 (30-35)
Dynamic Damper ................................... 52 (70)
High-Low Shift Rail Plug ..................... ( 1) 24 (33)
Interlock Plunger Plug ................. ( 1) 22-26 (30-35)
Lock Plate Bolts ........................... 11-16 (15-22)
Oil Dam Cover ................................ ( 1) 14 (19)
Oil Filler Plug ............................ 22-26 (30-35)
Output Shaft Cover Bolt .................... 11-16 (15-22)
Poppet Plug .................................. ( 1) 27 (36)
Pulse Rotor Bolt ....................... ( 2) 11-16 (15-22)
Rear Cover Bolt ............................ 11-16 (15-22)
Rear Output Shaft Lock Nut ............... 74-96 (100-130)
Seal Plug .............................. ( 2) 22-31 (30-42)
Speedometer Sleeve Clamp Bolt .............. 11-16 (15-22)
4WD Indicator Light Switch ................... ( 2) 22 (33)
INCH Lbs. (N.m)
Pulse Generator Bolt .................. ( 2) 89-106 (10-12)
Side Cover Bolt ............................. 71-89 (8-10)
( 1) - Montero.
( 2) - Ram-50.









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WIRING DIAGRAMS

\003
TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - A /T
1991 M it s u bis h i M onte ro
199192 TRANSMISSION SERVICING
Transmission Removal & Installation
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
MANUAL
NOTE: For manual transmission/transaxle replacement procedures,
see appropriate article in CLUTCHES.
AUTOMATIC FWD MODELS
REMOVAL
1) Remove battery and battery tray. On 3000GT, remove
undercover(s). On Eclipse turbo, drain and remove intercooler. On all
models, remove air cleaner and case. Raise and support vehicle. Remove
wheels. Disconnect control cables at transaxle. Drain transaxle fluid.
2) On Mirage 1.6L, disconnect tension rod. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) On Galant models with electronically controlled
suspension, remove air compressor and bracket. Disconnect front height
sensor rod at lower control arm.
4) On all models, remove upper transaxle-to-engine bolts.
Remove engine undercover (if equipped). On all models, remove drive
axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Separate
lower control arms from struts for access to axle shafts (if
necessary).
5) Remove front exhaust pipe (if necessary). On Eclipse 4WD,\
Galant 4WD and 3000GT, remove right member and gusset. On 4WD models,
separate transfer assembly from transaxle. Reference mark transfer
assembly-to-drive shaft and remove transfer assembly.
6) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
7) Support transaxle with jack. Remove transaxle mounts
bolts, mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
INSTALLATION
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. Adjust all control cables.
RWD MODELS

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)

RWD Models
Torque Converter-To-Drive Plate Bolt
Montero ...................................... 25-30 (34-41)
Pickup ....................................... 33-38 (45-52)
Transmission-To-Engine Block Bolt
Montero
10x40-mm Bolt .............................. 22-30 (30-41)
12x40-mm Bolt .............................. 47-61 (64-83)
12x55-mm Bolt .............................. 58-72 (79-98)
Pickup
10x16-mm Bolt .............................. 22-30 (30-41)
10x50-mm Bolt .............................. 31-40 (42-54)
10x70-mm Bolt .............................. 31-40 (42-54)
(1) - Tighten to 84-108 INCH lbs. (10-12 N.m).









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oil filter/screen, note length and location of all bolts.
TRANSAXLE (EXCEPT MONTERO, PICKUP & RAM-50)
1) Remove drain plug(s), and drain fluid. See Fig. 1. Some
applications may contain a drain plug located in housing below drive
axle shaft, in oil pan. Remove oil pan. Remove oil filter/screen if
necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Ensure dipstick hole area is clean, and pour approximately 4.2
qts. (4.0L) of Dexron-II fluid into dipstick hole.
3) Operate engine at idle for 2 minutes. Shift transaxle to
each position, ending in Neutral. Add sufficient fluid to reach lower
mark. After reaching normal operating temperature, fluid should be
between upper and lower marks of HOT range on dipstick.
Fig. 1: Locating Drain Plugs
Courtesy of Mitsubishi Motor Sales of America.
TRANSMISSION (MONTERO & PICKUP)
1) Remove drain plug (if equipped) from transmission pan, an\
d
allow fluid to drain. On models without drain plug, remove oil pan
must to drain fluid. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Fill transmission, through filler tube, with 5.3 qts. (5.0L) of\
Dexron-II ATF on Montero, or 2.0 qts. (1.9L) on all others. Start
engine, and allow to idle for 2 minutes.
3) Shift transmission into each position, ending in Neutral.
Check fluid level with engine running at idle, and add sufficient

specification, use the following trouble shooting guide.
* Hydraulic Pressure High In All Ranges
Check throttle cable adjustment. If adjustment is okay, check
for throttle valve or regulator valve failure.
* Hydraulic Pressure Low In All Ranges
Check throttle cable adjustment. If adjustment is okay, check
for throttle valve, regulator valve, transmission oil pump or
overdrive clutch failure.
* Hydraulic Pressure Low In Drive Position
Check for fluid leaks in Drive hydraulic circuit. Check for
forward clutch or overdrive clutch failure.
* Hydraulic Pressure Low In Reverse Position
Check for fluid leaks in Reverse hydraulic circuit. Check for
transmission No. 3 brake failure, forward clutch failure or
overdrive clutch failure.
LINE PRESSURE (PICKUP)
1) Incorrect throttle pressure setting will cause incorrect
line pressure readings even though line pressure adjustment is
correct. Always inspect and correct throttle pressure adjustment
before adjusting line pressure.
2) Approximate adjustment, measured from valve body to inner
edge of adjusting nut, is 15/16". However, due to manufacturing
tolerances, adjustment can be varied to obtain correct line pressure.
3) Adjusting screw may be turned with an Allen wrench. One
complete turn of adjusting screw changes closed throttle line pressure
approximately 1 2/3 psi. Turn adjusting screw counterclockwise to
increase pressure or clockwise to decrease pressure.
THROTTLE PRESSURE (PICKUP)
1) Throttle pressures cannot be accurately tested. If a
malfunction exists, adjustment should be measured.
2) Insert Gauge Pin (C-3763) between throttle lever cam and
kickdown valve. Push in on tool to compress kickdown valve against its
spring.
3) As force is being exerted to compress spring, turn
throttle lever screw with Allen wrench until head of screw touches
throttle lever tang with gauge pin, and throttle valve bottoms. Ensure
adjustment is made with spring fully compressed and valve bottomed in
valve body.
KICKDOWN BAND
PICKUP
1) Locate kickdown band adjusting screw on left side of
transmission case. Loosen lock nut, and back off nut 5 turns. Ensure
adjusting screw turns freely in transmission case.
2) Using torque wrench, tighten adjusting screw to 72 INCH
lbs. (8 N.m). Back off adjusting screw 2 7/8 turns. Hold adjuster
screw in this position, and tighten lock nut to 30 ft. lbs. (41 N.m).
LOW-REVERSE BAND
PICKUP
1) Raise vehicle, drain transmission, and remove oil pan.
Loosen adjusting screw lock nut, and back off nut 5 turns. Ensure

adjusting screw turns freely in lever.
2) Using torque wrench, tighten band adjusting screw to 30
INCH lbs. (3.5 N.m). Back off adjusting screw 6 turns. Hold adjusting
screw in this position, and tighten lock nut to 25 ft. lbs. (34 N.m).
3) Reinstall oil pan using new gasket. Tighten pan bolts to
150 INCH lbs. (17 N.m). Refill with specified transmission fluid.
KICKDOWN SERVO
ECLIPSE, GALANT, MIRAGE, PRECIS & 3000GT
1) Remove all dirt and grease around kickdown servo switch.
Remove snap ring and kickdown servo switch.
2) To prevent servo piston from turning, install Adapter
(MD998915) and Kickdown Servo Wrench (MD998914) so tab of wrench
engages with notch of piston. See Fig. 2.
CAUTION: DO NOT push servo piston inward while installing adapter
and servo wrench. Install adapter in brake pressure port by
hand ONLY. DO NOT use wrench to tighten adapter.
Fig. 2: Adjusting Kickdown Servo (Except Montero & Pickup)
Courtesy of Mitsubishi Motor Sales of America.
3) Loosen lock nut to "V" channel of adjuster rod. See
Fig. 2 . Tighten inner section of Kickdown Service Adjustment Assembly
(MD998916) until it contacts lock nut.
4) Install outer section of kickdown service adjustment
assembly on lock nut. Rotate outer section to left and inner section
to right to contact lock nut with inner section.
5) Using an INCH lb. torque wrench on inner section, tighten
inner section to 86 INCH lbs. (9.8 N.m), and then loosen inner
section. Tighten inner section to 43 INCH lbs. (4.9 N.m).
CAUTION: Before tightening lock nut with torque wrench, tighten it
by hand until it contacts piston. If torque wrench is used