service MITSUBISHI TRITON 1997 Service Manual

REAR AXLE ± Service Specifications27-4
SERVICE SPECIFICATIONS27100030121
ItemStandard valueLimit
Rear axle total backlash mm±5
Axle shaft axial play mmVehicles without ABS or rear differential lock0.05 ± 0.20±
Vehicles with ABS or rear differential lock0 ± 0.25±
Limited slip differential
p
reload Nm
Using special tool13 or more±
reload Nm
Without using special tool25 or more±
Axle shaft retainer
press-fitting force NVehicles without ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
78,000±
Vehicles with ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
98,000 ± 108,000±
Clearance between axle shaft retainer and snap ring mm0 ± 0.166±
Rear differential lock air pump pressure kPa25 ± 40±
Drive gear backlash mm2WD0.08 ± 0.13±
4WD0.13 ± 0.18±
Drive gear runout mm±0.05
Differential gear backlash mm2WD0 ± 0.250.2
4WD0 ± 0.0760.2
Limited slip differential
starting torque Nm
When a new clutch plate is used39 ± 74±
starting torque Nm
When re-installing current clutch plate25 ± 74±
Drive pinion
turning torque NmWithout oil sealWhen replacing
(with anti-rust agent)0.6 ± 0.9±
When replacing or reusing
(with gear oil applied)0.4 ± 0.5±
With oil sealWhen replacing
(with anti-rust agent)0.8 ± 1.1±
When replacing or
reusing (with gear oil applied)0.6 ± 0.7±

REAR AXLE ± Service Specifications/Lubricants/Sealants27-5
ItemStandard valueLimit
Horizontal difference between friction plate and friction disc thickness mm0 ± 0.05±
Clearance between friction plate and friction disc mm0.06 ± 0.20±
Clearance in side gear axial direction mm0.05 ± 0.20±
Difference between left and right dimensions from back thrust face of pressure
ring to end of thrust washer mm0 ± 0.05±
Friction plate and friction disc warping (flatness) mm±0.08
Friction plate and friction disc wear
(difference in the thickness of the friction surface and the projections) mm±0.1
LUBRICANTS27100040049
ItemSpecified lubricantsQuantity
Rear differential gear oil
Conventional differential:
Hypoid gear oil
API classification GL-5 or higher SAE viscosity No. 90,
80 W

Limited slipdifferential:
2WD1.6


Limited sli differential:
Hypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 8149630 EX
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL-5, SAE 80W-90) or equivalent4WD2.6

SEALANTS27100050042
ItemsSpecified sealantsRemarks
Bearing case3M ATD Part No. 8661 or equivalentSemi-drying sealant
Dust cover
Axle housing (differential carrier mounting part)
Drive gear and differential case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant

WHEEL AND TYRE ± General Information/Service Specifications31-2
GENERAL INFORMATION31100010146
Both steel type and aluminium type wheels have
been adopted. The type of wheel used depends
on the vehicle model.
Items2WD4WD
WheelTypeSteel typeSteel typeAluminium type
Size14 x 6JJ16 x 6JJ15 x 7JJ
Amount of wheel offset333310 +1
Pitch circle diameter
(P.C.D.) mm139.7139.7139.7
TyreSize185R 14C 8PR205/80 R16 RF31 x 10.50 R15 LT
SERVICE SPECIFICATIONS31100030036
ItemsLimit
Tread depth of tyre mm1.6
Wheel runout (Radial runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less
Wheel runout (Lateral runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less

FRONT SUSPENSION ± Service Specifications/Sealant33A-3
SERVICE SPECIFICATIONS33200030088
ItemsStandard valueLimit
Toe-inAt the centre of tyre thread mm0 ± 7±
Toe-angle
(per wheel)
2WD0
± 0
19'±
(er wheel)
4WD
<Vehicles with
205/80 R16 tyre>0
± 0
16'±
4WD
<Vehicles with 31
x 10.50 R15 tyre>0
± 0
15'±
Camber0
10' ± 1
10' (Difference between
right and left within 30')±
Caster2WD1
45' ± 3
45' (Difference between
right and left within 30')±
4WD1
15' ± 3
15' (Difference between
right and left within 30')±
Kingpin inclination2WD15
00'±
4WD14
50'±
Shock absorber attaching dimension mm1 ± 2±
Upper arm ball joint starting torque Nm2WD0.8 ± 3.4±
Strut bar attaching dimension mm79±
Lower arm ball joint end play mm±0.5
Lower arm bush press-fitting force kN9.8±
Clearance between bump stopper and
bump stopper bracket mm4WD21 ± 23±
Stabilizer link assembly attaching
dimension mm4WD16 ± 18±
SEALANT33200050015
ItemSpecified sealant
Upper arm ball joint dust cover <2WD>3M ATD Part No. 8661 or equivalent

REAR SUSPENSION ± On-vehicle Service34-3
ON-VEHICLE SERVICE34101100034
REAR WHEEL ALIGNMENT
The rear suspension assembly must be free of worn, loose
or damaged parts prior to measurement of rear wheel
alignment.
Standard value:
Toe-in 0 mm
Camber 0

NOTE
Toe-in and camber are set at the factory and cannot be
adjusted. If toe-in or camber is not within the standard value,
check and replace bent or damaged parts.

35A-2
BASIC BRAKE
SYSTEM
CONTENTS35109000197
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 5. . . . . . . . . . . . . . . . .
LUBRICANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 10. . . . . . . . . . . . . . . . . . . .
Brake Pedal Check and Adjustment 10. . . . . . . . . .
Stop Lamp Switch Check 11. . . . . . . . . . . . . . . . . . . . .
Brake Booster Operating Test 11. . . . . . . . . . . . . . . . .
Check Valve Operation Check 12. . . . . . . . . . . . . . .
Brake Booster Vacuum Switch Check
<Diesel-powered vehicles> 12. . . . . . . . . . . . . . . . . . .
Bleeding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Fluid Level Sensor Check 13. . . . . . . . . . . . . Load Sensing Spring Length Check and
Adjustment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Sensing Proportioning Valve Function
Test 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Pad Check and Replacement 15. . . . .
Front Disc Brake Rotor Check 16. . . . . . . . . . . . . . .
Brake Lining Thickness Check 17. . . . . . . . . . . . . . .
Brake Drum Inside Diameter Check 18. . . . . . . . . .
Brake Lining and Brake Drum Connection
Check 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PEDAL 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER AND BRAKE
BOOSTER 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VA LV E 2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DISC BRAKE 24. . . . . . . . . . . . . . . . . . . . .
REAR DRUM BRAKE 30. . . . . . . . . . . . . . . . . . . . .

BASIC BRAKE SYSTEM ± Service Specifications35A-5
SERVICE SPECIFICATIONS35100030119
ItemsStandard valueLimit
Brake pedal height mm176 ± 181±
Brake pedal free play mm3 ± 8±
Brake pedal to floor board clearance mm95 or more±
Load sensing proportioning
valve outputpressure kPa
2WDWhen load sensing
spring length is 190
3,625 (5,884)±
valve out ut ressure kPa
(Input pressure kPa)
s ring length is 190
mm (when unladen)5,390 (17,652)±
When load sensing
spring length is 215
mm (when laden)14,393 (17,652)±
4WDWhen load sensing
spring length is 190
4,309 (5,884)±
s ring length is 190
mm (when unladen)6,074 (17,652)±
When load sensing
spring length is 215
mm (when laden)16,310 (17,652)±
Load sensing spring length mm189 ± 193±
Booster push rod to master
cylinder piston clearance mmSingle brake boosterPetrol-powered ve-
hicles0.65 ± 1.05±
Diesel-powered ve-
hicles1.00 ± 1.40±
Tandem brake boosterVehicle which brake
booster of power
cylinder is 180 mm
and 205 mm in
effective diameter0.90 ± 1.30±
Vehicle which brake
booster of power
cylinder is 205 mm
and 230 mm in
effective diameter0.70 ± 1.10±
Front disc brake pad thickness mm102.0
Front brake disc thickness mm2422.4
Front brake disc run-out mm2WD±0.08
4WD±0,06
Front disc brake drag force (tangential force of wheel mounting bolts) N69 or less±
Rear drum brake lining thickness mm4.71.0
Rear drum inside diameter mm2WD254.0256.0
4WD270.0272.0
Front hub end play mm0.05±

ABS <2WD> ± Troubleshooting35B-5
TROUBLESHOOTING35201110143
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 ± How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
PhenomenonExplanation of phenomenon
System check soundWhen starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being
performed, and is not an abnormality.
ABS operation sound1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
ABS operation
(Long braking distance)For road surfaces such as snow-covered roads and gravel roads, the braking distance for
vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise
the customer to drive safely on such roads by lowering the vehicle speed and not being too
overconfident.
Shock during system
operation checkShock may be felt when the brake pedal is depressed slightly at a low driving speed. This
occurs due to ABS operation check (initial check at a vehicle speed of 8 km/h), and does
not indicate any malfunction.
Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the ªCommentº are satisfied when checking the trouble
symptom again.
DIAGNOSIS FUNCTION35201120108
DIAGNOSIS CODES CHECK
Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP 00 ± How to Use Troubleshooting/Inspection
Service Points.)
ERASING DIAGNOSIS CODES
Refer to GROUP 00 ± How to Use Troubleshooting/Inspection
Service Points.

ABS <2WD> ± Troubleshooting35B-7
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. 11, 12, 13, 14 Wheel speed sensor open circuit
or short circuitProbable cause
Code No. 21, 22, 23, 24 Wheel speed sensor abnormal
The ABS-ECU determines that an open circuit or short circuit occurs in more than
one line of wheel speed sensors.
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector

Malfunction of ABS-ECU
These codes are output at the following times:

When an open circuit cannot be found, but more than one wheel speed sensor
does not output any signal during driving at 8 km/h or higher.

When a chipped or plugged-up rotor tooth, etc. is detected.

When the sensor output drops and anti-lock control is continuously carried out
due to a defective sensor or a warped rotor.
Malfunction of wheel speed sensor

Malfunction of rotor

Malfunction of wheel bearing

Malfunction of wiring harness or connector

Malfunction of ABS-ECU
NG
Replace the ABS-ECU.
OK
Check trouble symptoms.
OK
Check the following connector.
C-62NG
RepairOK
Wheel bearing check. (Refer to GROUP
26 and 27 ± On-vehicle Service.)
OK
Rotor check. (Refer to P.35B-40.)NGReplace the rotor.
OK
Wheel speed sensor output voltage
check. (Refer to P.35B-24.)NGWheel speed sensor check. (Refer to
P.35B-39.)NGReplace the wheel speed sensor.
OK
Measure at the ABS-ECU connectors
C-62

Disconnect the connector and
measure from the harness side.

Resistance values between 10 ± 23,
7 ± 20, 8 ± 21 and 9 ± 22.
OK: 1.2 ± 1.4 kWNGCheck the following connectors.
A-01, A-07, F-01, F-16, D-01 and C-02NG
Repair
Wheel speed sensor installation check.NG
Repair
OK
Check trouble symptoms.NGCheck the harness wire between each
wheel speed sensor and ABS-ECU, and
repair if necessary.

ABS <2WD> ± Troubleshooting35B-8
Code No. 15 Wheel speed sensor (Abnormal output signal)Probable cause
A wheel speed sensor outputs an abnormal signal (other than an open or short-circuit).
Improper installation of wheel speed sensor

Malfunction of wheel speed sensor

Malfunction of rotor

Malfunction of wheel bearing

Malfunction of wiring harness or connector

Malfunction of ABS-ECU
NG
Replace the ABS-ECU.
OK
Check trouble symptoms.
OK
Wheel bearing check. (Refer to GROUP
26 and 27 ± On-vehicle Service.)OKCheck the harness wire between each
wheel speed sensor and ABS-ECU, and
repair if necessary.
OK
Rotor check. (Refer to P.35B-40.)NGReplace the rotor.
OK
Check the following connector.
C-62NG
Repair
OK
Wheel speed sensor output voltage
check (Refer to P.35B-24.)NGWheel speed sensor check. (Refer to
P.35B-39.)NGReplace the wheel speed sensor.
Wheel speed sensor installation check.NG
Repair
Code No. 16 Power supply systemProbable cause
The voltage of the ABS-ECU power supply drops lower or rises higher than the specified
value. If the voltage returns to the specified value, this code is no longer output.
Malfunction of wiring harness or connector.

Malfunction of ABS-ECU
Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill distilled water if
necessary.
OK
Check the battery.
OK
Check trouble symptoms.NGCheck the harnes wire between the igni-
tion switch and the ABS-ECU, and repair
if necessary.
OK
Check trouble symptoms.NGReplace the ABS-ECU.
OK
Check the following connector.
C-62NG
Repair
Measure at the ABS-ECU connector
C-62.

Disconnect the connector and
measure at the harness side.

Start the engine. Voltage between
13 ± Body earth
OK:System voltageNGCheck the following connectors.
C-88, C-86 and C-02NG
Repair