4WD MITSUBISHI MONTERO 1998 Owner's Manual

Diode (Active Trac 4WD Circuit) Behind right side of dash,
taped to harness.
Diode (Door Light Circuit) Behind left side of dash,
taped to harness.

LOCKING HUBS
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Locking Hubs
Montero, Montero Sport
DESCRIPTION
Vehicles are equipped with an automatic locking clutch.
Locking clutch engages, providing full time AWD operation, when 4WD
(4H) is selected at transfer case, at speeds up to 62 MPH. Selecting
center differential lock position (4HLc or 4HLLc), while in AWD at 4
MPH or less, provides 4WD operation. Center differential lock
disengages when 4H or 2H is selected. Locking clutch disengages when
2H is selected.
REMOVAL & INSTALLATION
AUTOMATIC LOCKING HUBS
Removal & Installation
1) Remove right side inner shaft for automatic locking clutch
removal. See INNER SHAFT & BEARING in
DIFFERENTIAL & AXLE SHAFTS - FRONT article. With inner shaft removed,
remove locking clutch engage switch. See Fig. 1.
2) Remove 4 inner shaft tube-to-differential mounting bracket
bolts. Pivot differential mounting bracket. Remove 4 inner shaft tube-
to-differential carrier assembly mounting bolts. Pull inner shaft tube
and automatic locking clutch out of differential carrier assembly.
3) To install, reverse removal procedure. Tighten inner shaft
tube bolts to 65 ft. lbs. (90 N.m) and locking clutch engage switch to\
26 ft. lbs.(36 N.m).
Fig. 1: Identifying Automatic Locking Clutch Components
Courtesy of Mitsubishi Motor Sales of America.
OVERHAUL

Pickup .......... 1996-97 ........... DS .............. NISSAN-5
Pulsar NX ....... 1989-90 ........... DS .............. NISSAN-6
Quest ........... 1997-98 ........... D/P ............. NISSAN-3
1996 ............. D/P ............. NISSAN-4
1994-95 ........... DS .............. NISSAN-5
Sentra .......... 1997-98 ........... D/P ............. NISSAN-3
1995-96 ........... D/P ............. NISSAN-4
1994 ............. DS .............. NISSAN-5
1993 ............. DS .............. NISSAN-6
200SX ........... 1997-98 ........... D/P ............. NISSAN-3
1995-96 ........... D/P ............. NISSAN-4
240SX ........... 1997-98 ........... D/P ............. NISSAN-3
1995-96 ........... D/P ............. NISSAN-4
300ZX ........... 1994-96 ........... D/P ............. NISSAN-4
1991-93 ........... DS .............. NISSAN-6
(1) - Location Definitions: D/P = Driver's & Passenger's Side,
DS = Driver's Side Only, SI = Side Impact.









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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - NISSAN-1







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Control Unit, Diagnosis 










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Inspect & If 
* Crash Zone Sensor ( 1) 

Damaged, Replace 
* Instrument Panel 

Component 
* Passenger Deactivation Switch 

(Even If Air 
* Spiral Cable 

Bag Did Not 
* Steering Wheel 

Deploy) 
* Wiring Harnesses 










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Comments 
* If any components are damaged or bent, they 

 must be replaced. 


* DO NOT attempt SRS wiring harness repairs. 










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(
1) - 4WD only. 











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INSPECTION PROCEDURES TABLE - NISSAN-2







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Control Unit, Diagnosis 


* Side Air Bag Module ( 1) 


* Satellite Sensor ( 1) 










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Inspect & If 
* Center Pillar Inner ( 1) 

Damaged, Replace 
* Instrument Panel 

Component 
* Seat ( 1) 

(Even If Air 
* Spiral Cable 

Bag Did Not 
* Steering Wheel 

Deploy) 
* Wiring Harnesses 










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Comments 
* If any components are damaged or bent, they 

 must be replaced. 

(1) - Except Pathfinder and Pickup. 

(
2) - 4WD Pickup only. 

(
3) - Pathfinder only. 











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INSPECTION PROCEDURES TABLE - NISSAN-6







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Control Unit, Diagnosis 


* Sensors In Affected Collision Area 










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Inspect & If 
* All Sensors Spiral Cable 

Damaged, Replace 
* Steering Wheel 

Component 
* Wiring Harnesses 

(Even If Air  

Bag Did Not  

Deploy)  










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Comments 
* If any components are damaged or bent, they 

 must be replaced. 


* DO NOT attempt SRS wiring harness repairs. 











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SUBARU (1992-98)
AIR BAG APPLICATION
AIR BAG APPLICATION TABLE - SUBARU (1992-98)








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Model Year (1) Location
Forester .............. 1998 ....................... D/P
Impreza ............. 1994-98 ...................... D/P
1993 ........................ DS
Legacy .............. 1995-98 ...................... D/P
1992-94 ....................... DS
SVX ................. 1994-97 ...................... D/P
1992-93 ....................... DS
( 1) - Location Definitions: D/P = Driver's & Passenger's
Side, DS = Driver's Side Only, SI = Side Impact.









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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - SUBARU (1992-98)







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Air Bag Control Module 


* Front Impact Sensors ( 1) 


* Side Air Bag Sensors ( 2) 










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Inspect & If 
* Air Bag Control Module 

Damaged, Replace 
* Combination Switch & Clockspring 

Component 
* Front Impact Sensors 

(Even If Air  

Bag Did Not  

Deploy)  

STEERING COLUMN
1998 Mitsubishi Montero
1997-98 STEERING
Mitsubishi - Steering Columns - RWD & 4WD
Mitsubishi: Montero, Montero Sport
DESCRIPTION & OPERATION
WARNING: Vehicle is equipped with a Supplemental Restraint System
(SRS) that includes an air bag located in steering wheel.
Use caution when working around steering column. Ensure
battery is disconnected before attempting any repair. DO NOT
apply electrical power to any component on steering column
without disconnecting air bag module (air bag could deploy).
Steering column consists of a collapsible steering shaft with
lower joint assembly. Vehicle is equipped with a Supplemental
Restraint System (SRS) that includes an air bag and clockspring
located in steering column wheel.
NOTE: For information not covered in this article, air bag
DIAGNOSIS & TESTING or DISPOSAL PROCEDURES, see AIR BAG
RESTRAINT SYSTEM article.
DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: Wait at least 60 seconds after disconnecting negative
battery cable before servicing SRS. System reserve capacitor
maintains SRS voltage for about 60 seconds after battery is
disconnected. Servicing SRS before 60-second period may
cause accidental air bag deployment and possible personal
injury.
To disable system, turn ignition switch to OFF position.
Disconnect and isolate negative battery cable end. Wait at least 60
seconds. To activate system, reconnect negative battery cable.
AIR BAG SERVICE PRECAUTIONS
The following precautions should be observed when working
with SRS:
* Disable SRS before servicing any SRS or steering column
component. Failure to do this may result in accidental air
bag deployment and possible personal injury. See DISABLING &
ACTIVATING AIR BAG SYSTEM.
* Wait at least 60 SECONDS after disabling air bag system. SRS
system retains enough voltage, for a short time after system
is disabled, to deploy air bag.
* After repairs, always turn ignition on to ensure SRS warning
light is working properly and no system faults are indicated.
* Always wear safety glasses when servicing or handling an air
bag.
* DO NOT expose air bag module and clockspring to temperatures
more than 200
F (93C).
* When placing a live air bag on a bench or other surface,
always face air bag and trim cover up, away from surface.
This will reduce motion of module if air bag accidentally

SUSPENSION - FRONT
1998 Mitsubishi Montero
1997-98 SUSPENSION
Mitsubishi - Front - 4WD & RWD
Montero, Montero Sport
DESCRIPTION
Independent front suspension uses double wishbone
construction with torsion bar. Components used with this system
include upper control arm, lower control arm, shock absorber,
stabilizer bar and steering knuckle. See Fig. 1.
Fig. 1: Exploded View Of 4WD Front Suspension (Montero Shown, Montero
Sport Similar)
Courtesy of Mitsubishi Motor Sales of America.

ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in
WHEEL ALIGNMENT section.
WHEEL BEARING
Preload
1) Using Socket (MB990954) and torque wrench, tighten axle
lock nut to 119 ft. lbs. (162 N.m) on Montero, 94-145 ft. lbs. (127-
196 N.m) on Montero Sport. Loosen nut to 0 ft. lbs. (0 N.m). Retighte\
n
nut to 18 ft. lbs. (25 N.m).
2) Loosen nut 30-40 degrees on Montero, 30 degrees on Montero
Sport. Install lock washer. If lock washer hole is not aligned with
lock nut hole, lock nut may be rotated up to 20 degrees to obtain
alignment. After setting preload, check hub turning resistance and
axial play (4WD only).
Hub Turning Resistance & Axial Play (4WD Only)
1) Using dial indicator, check front hub axial play. Axial
play should be 0.002" (0.05 mm) or less. Using INCH-lb. torque wrench
or spring scale attached to wheel stud, measure hub turning
resistance. Turning resistance should be 1.1-4.0 lbs. (5-18 N) on
Montero or 0.9-4.3 lbs. (4-19 N) on Montero Sport if measured using
spring scale, or 2.6-11.3 INCH lbs. (0.3-1.3 N.m) on both models if
measured using torque wrench.
2) Adjust wheel bearing so turning resistance and axial play
are within specification. If turning resistance and axial play cannot
be adjusted to specification, check wheel bearing condition and
installation.
Drive Axle End Play (4WD Only)
Install drive axle shim and snap ring. Push drive shaft in
toward knuckle. Measure clearance between drive flange and shim with a
feeler gauge. If clearance is not 0.016-0.028" (0.4-0.7 mm) replace
shim to bring clearance into specification.
BALL JOINT CHECKING
Lower Ball Joint
Place ball joint in soft-jawed vise. Install dial indicator
with stem resting on end of ball joint stud. Measure ball joint stud
end play. Replace ball joint if end play exceeds 0.012" (0.3 mm). For
ball joint replacement, see LOWER BALL JOINT under
REMOVAL & INSTALLATION .
Upper Ball Joint
1) Disconnect ball joint from steering knuckle. Place nut on
ball joint stud. Using INCH-lb. torque wrench, measure starting torque
required to rotate ball joint stud.
2) Starting torque should be 7-30 INCH lbs. (0.8-3.5 N.m).
Replace ball joint if starting torque is not within specification. For
ball joint replacement, see UPPER BALL JOINT under
REMOVAL & INSTALLATION .
REMOVAL & INSTALLATION
AXLE HUB ASSEMBLY

SUSPENSION - REAR
1998 Mitsubishi Montero
1997-98 SUSPENSION
Rear - RWD & 4WD
Montero, Montero Sport
DESCRIPTION
NOTE: For testing and diagnosis information on electronically
controlled shocks, see ELECTRONIC - Montero article.
Montero
Rear suspension system is multi-link type with shock
absorbers, coil springs, lateral rod and stabilizer bar. See Fig. 2.
Montero Sport
Rear suspension system is a leaf spring type with shock
absorbers and stabilizer bar. See Fig. 2.
Fig. 1: Exploded View Of Rear Suspension (Montero Sport)
Courtesy of Mitsubishi Motor Sales of America.

4WD Circuit, W/ Active Trac

TRANSMISSION REMOVAL & INSTALLATION - A/T
1998 Mitsubishi Montero
1997-98 TRANSMISSION SERVICING
Mitsubishi Transmission Removal & Installation
Diamante, Eclipse, Galant, Mirage, Montero, 3000GT
REMOVAL & INSTALLATION
AWD & FWD MODELS
Removal
1) On all models except Galant, remove battery and battery
tray. On 3000GT, remove washer tank. On all models, remove air cleaner
cover with air inlet hose assembly. Raise and support vehicle. Remove
wheels. Remove undercover(s) (if equipped). Disconnect control cable\
s
at transaxle. Drain transaxle fluid.
2) On AWD models, remove front exhaust pipe. 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) Separate tie rod end. Separate lower ball joint. Separate
stabilizer bar connection (if necessary). Remove axle shafts. See
appropriate AXLE SHAFTS article in DRIVE AXLES. Remove center
crossmember assembly.
4) On AWD models, separate transfer assembly from transaxle.
Reference mark transfer assembly-to-drive shaft and remove transfer
assembly.
5) 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.
6) On all 4-cylinder models, support engine. On all models,
support transaxle with jack. Remove bolts from transaxle mounts.
Remove 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 .
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. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
RWD & 4WD MODELS
Removal
1) Disconnect negative battery cable. On Montero 4WD, 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)\