boot MITSUBISHI MONTERO 1998 Service Manual

Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) - Application incorrect includes wrong bulb coating
or color.
( 2) - Determine cause and correct prior to repair or
replacement of part.









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CALIPER HARDWARE
CALIPER HARDWARE INSPECTION








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Condition Code Procedure
Bent ................... A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Dust boots on slider pin
(bolt) missing ......... C ... Require replacement of boots.
Dust boots on slider pin
(bolt) torn ............ A ... Require replacement of boots.
Missing ................. C ............ Require replacement.
Shim bent ............... A ............. ( 1) Require removal
or replacement.
Shim (OE standard)
missing ................ C ........ ( 2) Require replacement.
Shim out of position .... B ............. ( 1) Require removal
or replacement.
Shim worn ............... A ............. ( 1) Require removal
or replacement.
Slider pin (bolt) bent .. B ... Require replacement of slider
pin or bolt and lubricants.
Slider pin (bolt)
rust-pitted ............ A ... Require replacement of slider
pin or bolt and lubricants.
Slider pin (bolt) worn .. A ... Require replacement of slider
pin or bolt and lubricants.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Removal is acceptable if shim is not OE.
( 2) - Aftermarket shims may be suggested to reduce noise.









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CALIPERS
You are not required to replace or rebuild calipers in axle
sets. However, when replacing or rebuilding a caliper due to the
conditions that follow, you may suggest servicing, rebuilding, or
replacement of the other caliper (on the same axle) for improved
performance and preventive maintenance (for example, the part is close
to the end of its useful life, replacing the caliper may extend pad
life, or contribute to more balanced braking).
CAUTION: When installing loaded calipers, it is required that
friction material be matched in axle sets for consistent
braking characteristics.

CALIPER INSPECTION








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Condition Code Procedure
Bleeder port damaged .... A ... Require repair or replacement
of caliper.
Bleeder screw broken off
in caliper ............. A ........... (1) Require repair or
replacement of caliper.
Bleeder screw plugged ... A ........... ( 1) Require repair or
replacement of bleeder screw.
Bleeder screw seized .... A ......... ( 2) Require replacement
of caliper.
Casting corroded,
affecting structural
integrity .............. A ............ Require replacement.
Casting damaged, affecting
structural integrity ... A ............ Require replacement.
Dust boot around caliper
torn ................... A ..... Require replacement of dust
boot.
Leaking ................. A .. Require repair or replacement.
Mounting pin threads
damaged ................ A ... Require repair or replacement
of component with damaged
threads.
Mounting pin threads
stripped in caliper
bracket (threads
missing) ............... A ... Require repair or replacement
of caliper bracket.
Mounting pin threads
stripped in steering
knuckle (threads
missing) ............... A ... Require repair or replacement
of steering knuckle.
Mounting pin threads
stripped (threads
missing) ............... A ... Require repair or replacement
of component with stripped
threads.
Parking brake cable
support, lever, or return
spring bent ............ A ... Require replacement of parts.
Parking brake cable
support, lever, or return
spring broken .......... A ... Require replacement of parts.
Parking brake mechanism in
caliper inoperative .... A .. Require repair or replacement.
Piston corroded (pitted
or peeling chrome
plating) ............... B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, affecting
performance ............ B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, not
affecting performance .. .. ........ No service suggested or
required.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement

to the conditions that follow, you may suggest rebuilding or
replacement of the other wheel cylinder (on the same axle) for
preventive maintenance, for example, the part is close to the end of
its useful life.
Determine the need to rebuild or replace based upon the
individual wheel cylinder conditions that follow.
WHEEL CYLINDER INSPECTION









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Condition Code Procedure
Attaching hardware bent . B ..... Require replacement of bent
parts.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
parts.
Attaching hardware
loose .................. A .. Require repair or replacement.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bleeder port damaged (if
non-repairable) ........ A ............ Require replacement.
Bleeder screw broken off
in wheel cylinder (if non-
repairable) ............ A ........ (1) Require replacement.
Bleeder screw plugged ... A ........... ( 1) Require repair or
replacement of bleeder screw.
Bleeder screw seized .... A ........ ( 2) Require replacement.
Bore corroded (pitted) .. B ............ Require replacement.
Bore grooved ............ A ............ Require replacement.
Bore oversized .......... B ............ Require replacement.
Dust boot missing ....... C ..... Require replacement of dust
boot.
Dust boot torn .......... A . ( 3) Require replacement of dust
boot.
Leaking ................. A ....... ( 4) Require rebuilding or
replacement.
Piston corroded, affecting
performance ............ B ... Require replacement of piston
and rebuilding or replacement
of wheel cylinder.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement
of wheel cylinder.
Piston stuck in bore .... A .... Require replacement of wheel
cylinder.
Loose ................... B .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Only required if the hydraulic system must be opened.
( 2) - Seized is defined as bleeder screw that cannot be removed
after a practical attempt at removing. Only required if
the hydraulic system must be opened.

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert a clutch alignment tool to prevent
pressure plate and clutch disc from dropping. Loosen pressure plate
bolts gradually in a crisscross pattern to avoid warping pressure
plate flange during removal. Remove pressure plate and clutch disc.
See Fig. 3 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

DO NOT clean release bearing assembly in solvent. Inspect hydraulic
system components for fluid leakage. Inspect cylinder dust boot for
cracks or deterioration.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure depth from
clutch disc surface to head of rivet. Replace clutch disc if
measurement is less than .012" (.30 mm). See Fig. 4. Replace worn or
defective components as necessary.
Fig. 4: Measuring Clutch Disc (Typical)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS .
2) Clean release bearing sliding surface. Apply a light
coating of multipurpose grease to release bearing sliding surface.

Apply a very light coating of grease to input shaft splines. DO NOT
allow grease or dirt on clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
CLUTCH RELEASE BEARING & RELEASE FORK
Removal (2WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
clips, release bearing and carrier. Use a punch to remove shift arm
spring pin and release lever assembly. Remove shift arm, felt packing
and 2 return springs. See Fig. 5.
2) Ensure release bearing turns freely and smoothly under
light load. Replace bearing if noise, roughness or dryness is present.
DO NOT clean bearing in solvent. Use shop towel or compressed air
only.
Installation
1) Insert lever and shaft into left side of transmission
case. Place shift arm, felt packing and return springs on shaft
assembly. Apply grease to inside of bushing and oil seal lips. Apply
oil to felt packing.
2) Align shift arm pin and control shaft pin holes. Drive
spring pins into position, with slit area upward. Reverse removal
procedure to complete installation. Check pedal height and free play.
Adjust if necessary. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS.
Removal (4WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
spring or clips, and remove release bearing.
2) Slide release fork toward outside of transmission and
disengage from fulcrum ball. DO NOT slide release fork toward inside
of case, or damage to fulcrum ball clip will result. Remove release
fork boot.
Installation
To install, reverse removal procedure. Apply grease to
fulcrum ball contact area of release fork before installing. Fill
groove of release bearing inside diameter with grease before
installing. See Fig. 5.

CLUTCH RELEASE CYLINDER
Disassembly
Remove valve plate and spring. See Fig. 7. Remove push rod
and boot. Cover piston assembly opening with a rag. Slowly apply air
pressure to hydraulic line opening to force piston from body.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. To
reassemble, reverse disassembly procedure. Ensure piston moves freely
in bore.
Fig. 7: Exploded View Of Clutch Release Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Clutch Pedal Position Switch Adjusting Nut Or Bolt ......... 10 (13)\
Bellhousing-To-Engine Mounting Bolt
Montero
10 x 40 mm ............................................. 26 (36)\
10 x 55 mm ............................................. 22 (31)\
12 x 40 mm ............................................. 54 (75)\
12 x 55 mm ............................................. 65 (90)\
Montero Sport
2WD .................................................... 19 (26)\
4WD .................................................... 55 (75)\
Clutch Master Cylinder Mounting Nut ........................ 10 (13)\

Removal
1) Raise and support vehicle. Drain gear oil. Support
differential carrier. Remove axle shafts and inner shaft. See
AXLE SHAFTS R & I and
INNER SHAFT & BEARING . Place alignment mark on drive shaft and pinion
companion flange for reassembly reference.
2) Remove drive shaft. Remove differential mounting brackets
at differential and frame. See Fig. 1. Disconnect front crossmember
from frame. Remove differential carrier assembly and front
crossmember. Remove differential carrier from front crossmember.
Installation
To install, reverse removal procedure. Align marks on drive
shaft and pinion companion flange.
INNER SHAFT & BEARING
Removal
Remove right axle shaft. See AXLE SHAFTS R & I. Using slide
hammer, remove inner shaft from differential carrier. See Fig. 1. If
dust seal replacement is required, pry dust seal from housing tube
assembly using a screwdriver. To remove bearing, bend outer area of
dust cover inward on inner shaft. Press shaft out of bearing. Remove
dust cover from shaft.
Inspection
Inspect inner shaft for damaged splines or threads. Inspect
bearing for roughness or damage.
Installation
1) Install housing tube. Using Seal Installer (MB990955) and\
Handle (C-4171), install NEW dust seal in housing tube. Dust seal must\
be even with housing tube. Coat seal lip with grease.
2) Using a pipe with O.D. of 2.00" (75.0 mm), wall thickness\
of .16" (4.0 mm) and overall length of 2.00" (50.0 mm), install dust\
cover on shaft. Coat inside of dust cover with grease. Press bearing
on shaft. Install new circlip on inner shaft. Carefully drive inner
shaft into differential. DO NOT damage oil seal. To complete
installation, reverse removal procedure.
OVERHAUL
AXLE SHAFTS & BEARINGS
NOTE: References to BJ and DOJ refer to Birfield Joint and Double
Offset Joint, respectively.
Disassembly
1) Remove boot bands. Remove circlip from DOJ outer race.
Separate axle shaft from DOJ outer race. Remove balls from DOJ cage.
Remove DOJ cage from DOJ inner race in direction of BJ. See Fig. 2.
2) Remove snap ring from axle shaft shaft. Remove DOJ inner
race from shaft. Remove circlip from shaft. Wrap tape around splines
of shaft to prevent boot damage during removal. Remove DOJ boot. Note
size of boot. Remove dust cover from shaft. Move boot protector toward
BJ side of shaft and remove. Remove BJ boot.
CAUTION: Axle shaft and BJ are serviced as a unit. DO NOT attempt to
disassemble BJ and axle shaft.
Reassembly
1) Coat shaft with light coat of grease. Wrap splines with

tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Pack proper amount of grease in BJ and BJ boot. See
CV JOINT GREASE CAPACITY table. Boot bands must be installed so lever
is pulled toward rear of vehicle when band is tightened.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage. Apply
proper amount of grease to outer DOJ race. See
CV JOINT GREASE CAPACITY table. Install shaft into DOJ outer race.
Install circlip.
4) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between center line of boot
bands. Distance should be 3.03-3.27" (76.9-83.0 mm). This distance is
necessary to control air in DOJ boot. Tighten boot bands. Install boot
protector and band. Install dust cover on shaft.
CV JOINT GREASE CAPACITY









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Application ( 1) Ozs. (g)
BJ Boot & Joint
Montero ................................................ 4.6 (130)\
Montero Sport .......................................... 4.2 (120)\
DOJ Boot & Joint
Montero ................................................ 3.5 (100)\
Montero Sport .......................................... 4.9 (140)\
( 1) - Apply 1/2 of the amount of grease specified to joint, the other
half to inside of CV boot.









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DIFFERENTIAL ASSEMBLY
Disassembly
1) Remove differential carrier from vehicle. See
DIFFERENTIAL CARRIER ASSEMBLY under REMOVAL & INSTALLATION. Remove
cover. Mark bearing caps for reassembly reference. Remove bearing
caps. Remove differential case assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components
must be installed in original location.
2) Using bearing puller, remove differential case side
bearings. Loosen ring gear retaining bolts in diagonal sequence.
Remove ring gear. Remove drive pinion shaft lock pin from ring gear
side. Remove pinion shaft and pinion gears. Remove side gears and
thrust spacers.
Drive Pinion Removal
Remove pinion flange nut. Scribe alignment mark on pinion
companion flange and drive pinion. Remove flange. Using soft-faced
hammer, drive out pinion. Remove rear bearing and oil seal from
carrier. Remove rear adjusting shim from pinion. See Fig. 1. Press
front bearing from pinion. Remove front adjusting shim and spacer from
pinion.
Cleaning & Inspection
Use cleaning solvent to rinse gears and components. Check
bearings for wear or discoloration. Check gear carrier for cracks or
damage. Check pinion, side gear and flange splines for excessive wear.

* DRIVETRAIN SYSTEMS UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS