ABS MITSUBISHI MONTERO 1998 Owner's Manual
Page 172 of 1501
Disconnect electrical connector from output speed sensor. See
Fig. 15. Remove bolt and output speed sensor. To install, reverse
removal procedure.
Fig. 15: Locating Output Speed Sensor & Connector
Courtesy of Mitsubishi Motor Sales of America.
PARK/NEUTRAL POSITION (PNP) SWITCH
Removal
Switch is located on side of transmission. Remove manual
lever from control shaft on transmission. Bend up tabs on lock washer.
Remove lock nut, lock washer and seal from control shaft. Remove
retaining bolt and neutral safety switch.
Installation
1) Install switch on control shaft. Loosely install switch
retaining bolt. Install seal and lock washer. Install lock nut and
tighten to specification. See TORQUE SPECIFICATIONS.
2) Switch must be adjusted. Ensure parking brake is applied.
Temporarily install manual lever on control shaft. Place shift lever
in Neutral. Remove manual lever. Rotate switch and align reference
mark on switch with groove.
3) Hold switch in this position. Tighten retaining bolt to
specification. Bend tabs on lock washer over against lock nut. To
install remaining components, reverse removal procedure.
Page 185 of 1501
SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:\
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
demonstrating to their customers that they are serious about customer
satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
Page 188 of 1501
and make an informed decision about how to proceed.
BRAKES
SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION
Some states may have specifications that differ from OEM.
Check your local/state regulations. Where state or local laws are
stricter, they take precedence over these guidelines.
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCELEROMETER INSPECTION \
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B ....... Require re-positioning to
vehicle manufacturer's
specifications.
Output signal incorrect . B ............ Require replacement.
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ACCUMULATORS
ACCUMULATOR INSPECTION \
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Condition Code Procedure
Leaking ................. B ............ Require replacement.
Missing ................. C ............ Require replacement.
Pre-charge incorrect .... B ............ Require replacement.
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ANCHOR PINS
See BACKING PLATES .
ANTI-LOCK BRAKE SYSTEMS
NOTE: Anti-lock brakes are an integral part of the brake system. It
is essential that the anti-lock brakes function properly when
brake service is performed.
Anti-lock brake systems are commonly referred to as "ABS" and
will be referred to as "ABS" throughout these guidelines. Some ABS
components also function as part of a traction control system (TCS).
WARNING: When diagnosing and servicing high pressure components,
observe safety procedures and equipment requirements
established by the vehicle manufacturer to reduce the
possibility of serious personal injury.
NOTE: Intermittent electrical conditions are often caused by a loss
of ground, poor connection, or water intrusion into the
wiring harness.
Page 189 of 1501
NOTE: Electro-magnetic interference (EMI) may be caused by
incorrect installation of accessories or components. EMI can
result in improper system operation.
BACKING PLATES
BACKING PLATE INSPECTION \
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Condition Code Procedure
Anchor pin bent ......... B .. Require repair or replacement.
Anchor pin broken ....... A ............ Require replacement.
Anchor pin worn, affecting
structural integrity ... B ............ Require replacement.
Backing plate bent ...... B .. Require repair or replacement.
Backing plate broken .... A ............ Require replacement.
Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting
structural integrity .... A ............ Require replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Shoe lands worn ......... A .. Require repair or replacement.
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BRAKE FLUID
CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid
in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light
amber in color. DOT 5 brake fluid is violet in color. Correct fluid
required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION
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Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling
with correct fluid.
Brake fluid type
incorrect .............. B .. Require flushing and refilling
with correct fluid.
Contaminated, for example,
fluid other than brake
fluid present .......... A or B ....... ( 1) Require service.
Hydraulic component ..... 3 .. Suggest flushing and refilling
overhaul or replacement with correct fluid.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .......... ( 2) Require replacement
of gasket.
( 1) - If a fluid other than brake fluid is present in the brake
system which DOES affect the rubber parts, the required
service is to:
* Remove all components having rubber parts from the
system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake
Page 211 of 1501
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Condition Code Procedure
Tire diameter incorrect,
affecting ABS or TCS ... A ............ Require replacement.
Tire pressure incorrect,
affecting ABS or TCS ... A .. Require repair or replacement.
Tire size incorrect,
affecting ABS or TCS ... A ............ Require replacement.
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TOOTHED RINGS (TONE WHEEL)
NOTE: Copied from Drivetrain UIGs.
If the toothed ring requires replacement and cannot be
replaced as a separate component, replace the assembly of which the
ring is a part.
TOOTHED RING INSPECTION
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Condition Code Procedure
Alignment incorrect ..... B ............... Require repair or
replacement.
Bent .................... B ............ Require replacement.
Contaminated, affecting
performance ............. A ........ Require repair. Identify
and correct cause.
Cracked ................. B ............ Require replacement.
Loose ................... A ............. Require replacement
of worn parts.
Missing ................. C ............ Require replacement.
Number of teeth
incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.
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VACUUM BOOSTERS
VACUUM BOOSTER INSPECTION \
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Condition Code Procedure
Applies too much assist
(oversensitive) ........ A ............ Require replacement.
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.
Auxiliary vacuum pump
inoperative ............ A ........... ( 1) Require repair or
replacement.
Check valve grommet
deteriorated, affecting
performance ............ A .. Require replacement of grommet.
Page 227 of 1501
pressure at specified pressure range (split point). See
SPLIT POINT PRESSURE SPECIFICATIONS table.
SPLIT POINT PRESSURE SPECIFICATIONS
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Application psi (kg/cm)
Diamante .......................................... 312-383 (22-27)\
Eclipse
Without ABS ...................................... 320-391 (22-27)\
With ABS ......................................... 320-391 (22-27)\
Galant ............................................. 462-533 (33-38)\
Mirage
2-Door ........................................... 320-392 (22-26)\
4-Door ........................................... 391-463 (27-32)\
Montero Sport .................................................. ( 1)
( 1) - Information not available from manufacturer.
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3) Continue depressing brake pedal, and check readings on
pressure gauges. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS
table. If fluid pressures or split point are not within specification,
replace proportioning valve.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS
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Application/ Inlet Pressure (1) Outlet Pressure
Model psi (kg/cm) psi (kg/cm)
Diamante ................... 1138 (80) ........... 676-747 (48-53\
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Eclipse
With ABS ................. 996 (69) ............ 569-640 (39-44\
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Without ABS .............. 925 (61) ............ 462-533 (32-37\
)
Galant ..................... 996 (69) ................... 604 (43\
)
Mirage
2-Door ................... 1422 (98) ........... 566-680 (39-47\
)
4-Door ................... 1422 (98) ........... 619-733 (43-51\
)
3000GT
Hatchback ................ 906 (64) ............ 651-723 (46-51\
)
Convertible .............. 1117 (79) ........... 846-917 (60-65\
)
Montero Sport ................. ( 1) .......................... ( 1)
( 1) - Information is not available from manufacturer.
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REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
CAUTION: DO NOT remove or contaminate special grease coating on lock
pins.
Removal & Installation (Except 3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
lower lock pin or sleeve bolt. See Figs. 13-15. Lift caliper body
upward. Support caliper aside. Remove shims and pads from support
mounting. Remove pad clips.
2) If installing new pads, compress piston to bottom of bore.
Install retaining clips, pads and shims. Start engine and depress
brake pedal several times to expand caliper piston. Check brake fluid
level.
Page 230 of 1501
Fig. 10: Exploded View Of Parking Brake Assembly (Typical With Rear
Disc Brakes - Except Diamante)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Shoe-to-anchor spring must be installed correctly for proper
functioning of parking brakes.
Installation
1) To install, reverse removal procedure. When installing
shoe-to-anchor spring, ensure spring is installed correctly. When
installing adjuster, install left adjuster with adjusting bolt facing
vehicle front and right adjuster with adjusting bolt facing vehicle
rear.
2) On models with ABS, ensure gap between rotor teeth and
speed sensor pole piece is 0.008-0.039" (0.20-1.00 mm).
Removal (3000GT)
1) Raise and support vehicle. Remove rear wheel(s).
Disconnect rear speed sensor. Remove rear disc brake calipers and
Page 236 of 1501
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Removal & Installation (3000GT AWD Models)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). Remove caliper and rotor.
2) Remove 4 bolts and separate rear drive axle from hub
companion flange. Using Yoke Holder (MB990767), hold rear axle hub and\
remove axle nut at companion flange.
3) Using slide hammer and Hub Adapter (MB991354), remove axl\
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shaft from knuckle. Place axle in hydraulic press. Using an
appropriate bearing splitter, remove ABS rotor (if equipped) and outer\
axle bearing.
4) Remove inner bearing and seal from axle. Using Bearing
Installer Handle (MB990938) and Adapter (MB990931), install bearing
and axle seal.
5) Using Installer (MB990799), install dust shield onto axle\
shaft. Using hydraulic press, install outer axle bearing onto axle
shaft so seal lip is facing towards axle shaft. Press on wheel speed
sensor rotor (if equipped) with groove on speed sensor rotor is facing\
towards axle shaft flange.
6) Install axle shaft assembly into knuckle and tighten axle
nut to 188-217 ft. lbs. (260-300 N.m.). To complete installation,
reverse removal procedure. Tighten bolts to specification.
OVERHAUL
NOTE: For exploded views of calipers, see Figs. 13 through 17. For
exploded view of master cylinder, see Fig. 18.
Fig. 13: Exploded View Of Single Piston Caliper Assembly (Except
Montero Sport)
Courtesy of Mitsubishi Motor Sales of America.
Page 244 of 1501
Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Drum Inside Diameter (Maximum) ........................... 9.1 (231\
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Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter
With ABS .............................................. 1.0 (25.4)\
Without ABS ........................................... .93 (23.8)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\
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BRAKE SPECIFICATIONS (GALANT) \
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Application In. (mm)\
Booster Pushrod Clearance
Single Booster ............................... .024-.031 (.60-.80)\
Tandem Booster ............................... .016-.024 (.40-.60)\
Disc Runout ............................................. .003 (.08)\
Disc Thickness (Minimum) ................................ .88 (22.4\
)
Drum Inside Diameter (Maximum) ........................... 9.1 (231\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\
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BRAKE SPECIFICATIONS (MIRAGE) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.033 (.65-.85)\
Disc Runout ........................................... .006 (.0024)\
Disc Thickness (Minimum) ................................ .65 (16.4\
)
Drum Inside Diameter (Maximum) ........................... 8.1 (206\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ........................ .87 (22.22)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\
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BRAKE SPECIFICATIONS (MONTERO) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.035 (.65-.90)\
Disc Runout
Front ................................................. .004 (.10)\
Rear .................................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. 1.0 (25.4)\
Rear .................................................. .65 (16.4)\
Hub End Play ........................................... .0098 (.25)\
Master Cylinder Inside Diameter ........................ .937 (23.8)\
Pad Lining Thickness (Minimum)
Front ................................................. 1.08 (2.0)\
Rear ........................................................ (1)
Parking Brake Drum Diameter (Maximum) .................. 7.795 (198\
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Page 372 of 1501
AXLE SHAFT R & I
Removal (Montero & Montero Sport)
Block front wheels. Raise and support rear axle housing.
Remove brake caliper and rotor. See Fig. 3. Remove parking brake cable
attaching bolts. Remove connection for parking brake cable end from
rear brake assembly. Remove ABS speed sensor (if equipped). Unbolt
backing plate with bearing housing from rear axle housing. Using
Puller (MB990241) and Slide Hammer (MB990211), remove axle assembly.\
DO NOT damage oil seal. Remove "O" ring. Replace if necessary.
Installation
Install NEW oil seal in axle housing as needed. To install
axle assembly, reverse removal procedure.
Fig. 3: Exploded View Of Typical Axle Shaft
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Insert new "O" ring and shim of .04" (1.0 mm) thickness