MITSUBISHI MONTERO 1998 Service Manual

Dry or binding clutch Lubricate and align
pedal hub components
Floor mat interference Lay mat flat in proper
with pedal area
Dry or binding ball/fork Lubricate and align
pivots components
Faulty clutch cable Replace clutch cable









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Noisy Clutch Faulty interlock switch Replace interlock
Pedal switch
Self-adjuster ratchet Lubricate or replace
noise self-adjuster
Speed control interlock Lubricate or replace
switch interlock switch









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Clutch Pedal Binding clutch cable See CLUTCH article
Sticks Down
Springs weak in pressure Replace pressure plate
plate
Binding in clutch linkage Lubricate and free
linkage









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Noisy Dry release bearing Lubricate or replace
release bearing
Dry or worn pilot bearing Lubricate or replace
bearing
Worn input shaft bearing Replace bearing









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Transmission Weak springs in pressure Replace pressure plate
Click plate
Release fork loose on ball Replace release fork
stud and/or ball stud
Oil on clutch disc damper Replace clutch disc
Broken spring in slave Replace slave cylinder
cylinder









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DRIVE AXLE - NOISE DIAGNOSIS
Unrelated Noises
Some driveline trouble symptoms are also common to the
engine, transmission, wheel bearings, tires, and other parts of the
vehicle. Ensure cause of trouble actually is in the drive axle before
adjusting, repairing, or replacing any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and
have to be considered in pre-diagnosis. The 4 most common noises are
exhaust, tires, CV/universal joints and wheel trim rings.

In certain conditions, the pitch of the exhaust gases may
sound like gear whine. At other times, it may be mistaken for a wheel
bearing rumble.
Tires, especially radial and snow, can have a high-pitched
tread whine or roar, similar to gear noise. Also, some non-standard
tires with an unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or
excessive driveline play that can be improperly diagnosed as drive
axle problems.
Trim and moldings also can cause a whistling or whining
noise. Ensure none of these components are causing the noise before
disassembling the drive axle.
Gear Noise
A "howling" or "whining" noise from the ring and pinion gear
can be caused by an improper gear pattern, gear damage, or improper
bearing preload. It can occur at various speeds and driving
conditions, or it can be continuous.
Before disassembling axle to diagnose and correct gear
noise, make sure that tires, exhaust, and vehicle trim have been
checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick
against the spokes of a spinning bicycle wheel. It occurs while
decelerating from 40 MPH and usually can be heard until vehicle comes
to a complete stop. The frequency varies with the speed of the
vehicle.
A chuckle that occurs on the driving phase is usually caused
by excessive clearance due to differential gear wear, or by a damaged
tooth on the coast side of the pinion or ring gear. Even a very small
tooth nick or a ridge on the edge of a gear tooth is enough the cause
the noise.
This condition can be corrected simply by cleaning the gear
tooth nick or ridge with a small grinding wheel. If either gear is
damaged or scored badly, the gear set must be replaced. If metal has
broken loose, the carrier and housing must be cleaned to remove
particles that could cause damage.
Knock
This is very similar to a chuckle, though it may be louder,
and occur on acceleration or deceleration. Knock can be caused by a
gear tooth that is damaged on the drive side of the ring and pinion
gears. Ring gear bolts that are hitting the carrier casting can cause
knock. Knock can also be due to excessive end play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic
transmission is engaged in Reverse or Drive, or when throttle is
applied or released. It is caused by backlash somewhere in the
driveline, but not necessarily in the axle. To determine whether
driveline clunk is caused by the axle, check the total axle backlash
as follows:
1) Raise vehicle on a frame or twinpost hoist so that drive
wheels are free. Clamp a bar between axle companion flange and a part
of the frame or body so that flange cannot move.
2) On conventional drive axles, lock the left wheel to keep
it from turning. On all models, turn the right wheel slowly until it
is felt to be in Drive condition. Hold a chalk marker on side of tire
about 12" from center of wheel. Turn wheel in the opposite direction
until it is again felt to be in Drive condition.
3) Measure the length of the chalk mark, which is the total

axle backlash. If backlash is one inch or less, drive axle is not the
source of clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle.
It is usually caused by malfunctioning pinion bearings. Pinion
bearings operate at drive shaft speed. Roller wheel bearings may whine
in a similar manner if they run completely dry of lubricant. Bearing
noise will occur at all driving speeds. This distinguishes it from
gear whine, which usually comes and goes as speed changes.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. It is
usually caused by a malfunctioning wheel bearing. The lower pitch is
because the wheel bearing turns at only about 1/3 of drive shaft
speed.
Chatter On Turns
This is a condition where the entire front or rear of vehicle
vibrates when vehicle is moving. The vibration is plainly felt as well
as heard. Extra differential thrust washers installed during axle
repair can cause a condition of partial lock-up that creates this
chatter.
Axle Shaft Noise
Axle shaft noise is similar to gear noise and pinion bearing
whine. Axle shaft bearing noise will normally distinguish itself from
gear noise by occurring in all driving modes (Drive, cruise, coast and
float), and will persist with transmission in Neutral while vehicle is
moving at problem speed.
If vehicle displays this noise condition, remove suspect
axle shafts, replace wheel seals and install a new set of bearings.
Re-evaluate vehicle for noise before removing any internal components.
Vibration
Vibration is a high-frequency trembling, shaking or grinding
condition (felt or heard) that may be constant or variable in level
and can occur during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can
be divided into 3 main groups:
* Vibrations of various unbalanced rotating parts of the
vehicle.
* Resonance vibrations of the body and frame structures caused
by rotating of unbalanced parts.
* Tip-in moans of resonance vibrations from stressed engine or
exhaust system mounts or driveline flexing modes.
DRIVE AXLE - RWD 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. For definitions
of listed noises or sounds, see DRIVE AXLE - NOISE DIAGNOSIS
under POWERTRAIN.
DRIVE AXLE (RWD) TROUBLE SHOOTING









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CONDITION POSSIBLE CAUSE CORRECTION

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Knocking or Clunking
Differential Side Gear
Clearance Check Clearance
Worn Pinion Shaft Replace Pinion Shaft
Axle Shaft End Play Check End Play
Missing Gear Teeth Check Differential/
Replace Gear
Wrong Axle Backlash Check Backlash
Misaligned Driveline Realign Driveline









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Clinking During Engagement
Side Gear Clearance Check Clearance
Ring and Pinion Backlash Check Backlash
Worn/Loose Pinion Shaft Replace Shaft/Bearing
Bad "U" Joint Replace "U" Joint
Sticking Slip Yoke Lube Slip Yoke
Broken Rear Axle Mount Replace Mount
Loose Drive Shaft Flange Check Flange









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Click/Chatter On Turns
Differential Side Gear
Clearance Check Clearance
Wrong Turn On Plates (1) Replace Clutch Plates
Wrong Differential
Lubricant ( 1) Change Lubricant









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Knock Or Click Flat Spot on Rear
Wheel Bearing Replace Wheel Bearing









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Low Vibration At All Speeds
Faulty Wheel Bearing Replace Wheel Bearing
Faulty "U" Joint Replace "U" Joint
Faulty Drive Shaft Balance Drive Shaft
Faulty Companion Flange Replace Flange
Faulty Slip Yoke Flange Replace Flange
( 1) - Limited slip differential only.









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FWD AXLE SHAFTS & CV JOINTS 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 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

knuckles steering linkage
Rack and pinion mounting Tighten all mounting
loose bolts
Rack and pinion out of See adjustment in
adjustment STEERING article
Tie rod end loose Tighten and check
steering linkage
Excessive Pitman shaft-to- Repair as necessary
ball nut lash









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Poor Lack of lubricant in ball Lubricate and service
Returnability joint or linkage systems
Binding in linkage or ball See STEERING LINKAGE
joints and SUSPENSION article
Improper front end alignment See WHEEL ALIGNMENT
article
Improper tire pressure Inflate to proper
pressure
Tie rod binding Inflate to proper
pressure
Shaft seal rubbing shaft See STEERING COLUMN
article









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Excessive Improper tire pressure Inflate to proper
Vertical Motion pressure
Tires, wheels or rotors Balance tires then
out of balance check wheels and
rotors
Worn or faulty shock Check and replace if
absorbers necessary
Loose tie rod ends or Tighten or replace if
steering necessary
Loose or worn wheel See SUSPENSION article
bearings









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Steering Pulls Improper tire pressure Inflate to proper
to One Side pressure
Front tires are different Rotate or replace if
sizes necessary
Wheel bearings not See FRONT SUSPENSION
article
adjusted properly
Bent or broken suspension See FRONT SUSPENSION
components article
Improper wheel alignment See WHEEL ALIGNMENT
article

Brakes dragging See BRAKES article








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Instability Low or uneven tire Inflate to proper
pressure pressure
Loose or worn wheel See FRONT SUSPENSION
bearings article
Loose or worn idler arm See FRONT SUSPENSION
bushing article
Loose or worn strut See FRONT SUSPENSION
bushings article
Incorrect front wheel See WHEEL ALIGNMENT
alignment article
Steering gear not See MANUAL STEERING
centered GEARS article
Springs or shock Check and replace if
necessary
Improper cross shaft See MANUAL STEERING
GEARS article









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POWER STEERING 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 POWER STEERING TROUBLE SHOOTING CHART









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CONDITION POSSIBLE CAUSE CORRECTION








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Rattle or Pressure hoses touching Adjust to proper
Chucking Noise engine parts clearance
Loose Pitman shaft Adjust or replace if
necessary
Tie rods ends or Pitman Tighten and check system
arm loose
Rack and pinion mounts Tighten all mounting
loose bolts
Free play in worm and See POWER STEERING GEAR
article
Loose sector shaft or See POWER STEERING GEAR
thrust bearing adjustment
Free play in pot coupling See STEERING COLUMN
article

Worn shaft serrations See STEERING COLUMN
article









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Growl in Excessive pressure in Restricted hoses, see
Steering Pump hoses POWER STEERING GEAR
article
Scored pressure plates See POWER STEERING GEAR
article
Scored thrust plates or See POWER STEERING GEAR
rotor article
Extreme wear of cam ring See POWER STEERING GEAR
article









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Rattle in Vanes not installed See POWER STEERING PUMP
Steering Pump article
Vanes sticking in rotor See POWER STEERING PUMP
article









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Swish noise in Defective flow control See POWER STEERING PUMP
Pump valve article









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Groan in Air in fluid See POWER STEERING PUMP
Steering Pump article
Poor pressure hose Tighten and check,
connection replace if necessary









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Squawk When Damper "O" ring on valve See POWER STEERING PUMP
Turning spool cut article









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Moan or Whine Pump shaft bearing scored Replace bearing and
in Pump fluid
Air in fluid or fluid See POWER STEERING PUMP
level low article
Hose or column grounded Check and replace if
necessary
Cover "O" ring missing See POWER STEERING PUMP
or damaged article
Valve cover baffle See POWER STEERING PUMP
missing or damaged article
Interference of See POWER STEERING PUMP
components in pump article
Loose or poor bracket Correct or replace if
alignment necessary









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Hissing When Internal leakage in Check valved assembly
Parking steering gear first









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Chirp in Loose or worn power Adjust or replace if
Steering Pump steering belt necessary









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Buzzing When Noisy pump See POWER STEERING PUMP
Not Steering article

Free play in steering See STEERING COLUMN
shaft bearing article
Bearing loose on shaft See STEERING COLUMN
serrations article









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Clicking Noise Pump slippers too long See POWER STEERING PUMP
in Pump article
Broken slipper springs See POWER STEERING PUMP
article
Excessive wear or nicked See POWER STEERING PUMP
rotors article
Damaged cam contour See POWER STEERING PUMP
article









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Poor Return of Wheel rubbing against See STEERING COLUMN
Wheel turn signal SWITCHES article
Flange rubbing steering See STEERING COLUMN
gear adjuster article
Tight or frozen steering See STEERING COLUMN
shaft bearing article
Steering gear out of See POWER STEERING GEAR
adjustment article
Sticking or plugged See POWER STEERING PUMP
spool valve article
Improper front end See WHEEL ALIGNMENT
alignment article
Wheel bearings worn or See FRONT SUSPENSION
loose article
Ties rods or ball joints Check and replace if
binding necessary
Intermediate shaft joints See STEERING COLUMN
binding article
Kinked pressure hoses Correct or replace if
necessary
Loose housing head See POWER STEERING GEAR
spanner nut article
Damaged valve lever See POWER STEERING GEAR
article
Sector shaft adjusted See ADJUSTMENTS in POWER
too tight STEERING GEAR article
Worm thrust bearing See ADJUSTMENTS in POWER
adjusted too tight STEERING GEAR article
Reaction ring sticking See POWER STEERING GEAR
in cylinder article

Reaction ring sticking See POWER STEERING GEAR
in housing head article
Steering pump internal See POWER STEERING PUMP
leakage article
Steering gear-to-column See STEERING COLUMN
misalignment article
Lack of lubrication in Service front suspension
linkage
Lack of lubrication in Service front suspension
ball joints









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Increased Effort High internal pump leakage See POWER STEERING PUMP
When Turning article
Wheel Fast Power steering pump belt Adjust or replace if
Foaming, Milky slipping necessary
Power Steering
Fluid, Low Fluid Low fluid level Check and fill to
Level or Low proper level
Pressure
Engine idle speed to low Adjust to correct
setting
Air in pump fluid system See POWER STEERING PUMP
article
Pump output low See POWER STEERING PUMP
article
Steering gear See POWER STEERING GEAR
malfunctioning article









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Wheel Surges Low fluid level Check and fill to proper
or Jerks level
Loose fan belt Adjust or replace if
necessary
Insufficient pump See POWER STEERING PUMP
pressure article
Sticky flow control valve See POWER STEERING PUMP
article
Linkage hitting oil pan Replace bent components
at full turn









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Kick Back or Air in pump fluid system See POWER STEERING PUMP
Free Play article
Worn poppet valve in See POWER STEERING PUMP
steering gear article
Excessive over center See POWER STEERING GEAR
lash article
Thrust bearing out of See POWER STEERING GEAR
adjustment article