clutch MITSUBISHI MONTERO 1991 Owners Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 1204 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual in the section(s) you are accessing.
BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART
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BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART
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in the section(s) you are accessing.
BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Engine Lopes At Intake manifold-to-head Replace manifold
Idle leaks gasket, See ENGINES
Blown head gasket Replace head gasket,
See ENGINES
Worn timing gears, chain Replace gears, chain or
or sprocket sprocket
Worn camshaft lobes Replace camshaft, See
ENGINES
Overheated engine Check cooling system,
See COOLING
Blocked crankcase vent Remove restriction
valve
Leaking EGR valve Repair leak and/or
replace valve
Faulty fuel pump Replace fuel pump
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Engine Has Low Leaking fuel pump Repair leak and/or
Power replace fuel pump
Excessive piston-to-bore Install larger pistons,
clearance See ENGINES
Sticking valves or weak Check valve train
valve springs components, See ENGINES
Incorrect valve timing Reset valve timing, See
ENGINES
Worn camshaft lobes Replace camshaft, See
ENGINES
Blown head gasket Replace head gasket.
See ENGINES.
Clutch slipping Adjust pedal and/or
replace components, See
ENGINES
Engine overheating Check cooling system,
See COOLING
Auto. Trans. pressure
regulator valve faulty Replace pressure
regulator valve
Auto. Trans. fluid level Add fluid as necessary
too low
Improper vacuum diverter
valve operation Replace vacuum diverter
valve
Vacuum leaks Inspect vacuum system
and repair as required
Leaking piston rings Replace piston rings,
See ENGINES
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Faulty High Low fuel pump volume Replace fuel pump
Speed Operation
Leaking valves or worn Replace valves and/or
springs, See ENGINES
Incorrect valve timing Reset valve timing,See
ENGINES
Intake manifold restricted Remove restriction
Worn distributor shaft Replace distributor
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Faulty Improper fuel pump stroke Remove pump and reset
Acceleration pump stroke
Page 1219 of 1333
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article
Open solenoid pull-in See Testing in STARTER
wire article
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Starter Does Not Weak battery or dead Charge or replace
Operate and cell battery as necessary
Headlights Dim
Loose or corroded battery Check that battery
connections connections are clean
and tight
Internal ground in See Testing in STARTER
starter windings article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article
shoes
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Starter Turns Starter clutch slipping See STARTER article
but Engine
Does Not Rotate
Broken clutch housing See STARTER article
Pinion shaft rusted or See STARTER article
dry
Engine basic timing See Ignition Timing in
incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and
flywheel check for starter pinion
gear damage
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Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and
check for starter pinion
gear damage
Armature shaft sheared See STARTER article
or reduction gear teeth
stripped
Weak battery Charge or replace
battery as necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground
Page 1220 of 1333
connections for
tight and clean
connections
Ignition switch faulty Adjust or replace
or misadjusted ignition switch as
necessary
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Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary
Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid
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Starter Relay Dead battery Charge or replace
Page 1221 of 1333
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay
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Starter Drive Starter motor loose on Tighten starter
Will Not mountings attach bolts
Disengage
Worn drive end bushing See STARTER article
Damaged engine flywheel Replace flywheel and
teeth starter pinion gear for
damage
Drive yolk return spring Replace return spring
broken or missing
Faulty ignition switch Replace ignition switch
Insufficient clearance Replace starter
between winding leads to solenoid
solenoid terminal and main
contact in solenoid
Starter clutch not Replace starter clutch
disengaging
Ignition starter switch Replace ignition switch
contacts sticking
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Starter Relay Faulty solenoid switch, Check all wiring
Operates but switch connections or between relay and
Solenoid Does Not solenoid or replace
relay or solenoid as
necessary
Broken lead or loose Repair wire or wire
soldered connections connections as
necessary
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Solenoid Plunger Weak battery Charge or replace
Vibrates When battery as necessary
Switch is Engaged
Solenoid contacts Clean contacts or
corroded replace solenoid
Faulty wiring Check all wiring
leading to solenoid
Broken connections inside Repair connections or
switch cover replace solenoid
Open hold-in wire Replace solenoid
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Low Current Draw Worn brushes or weak Replace brushes or
brush springs as
necessary
Page 1231 of 1333
Excessive Noise Loose pump-to-drive Tighten screws
assembly screws
Loose tube on pump assembly Tighten tube
Valves not functioning Replace valves
properly
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Oil Leakage Loose end plug Tighten end plug
Bad seal crimp Remove and re-crimp
seal
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MANUAL TRANSMISSION
MANUAL TRANSMISSION 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.
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING
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Condition Possible Cause \
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Noisy In Forward Gears .Low gear oil level,
.Loose bell housing bolts,
.Worn bearings or gears
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Clunk On Deceleration
(FWD Only) .Loose engine mounts,
.Worn inboard CV joints,
.Worn differential pinion shaft,
.Side gear hub counterbore
in case worn oversize
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Gear Clash When Shifting
Forward Gears .Clutch Out Of Adjustment,
.Shift linkage damaged or
out of adjustment,
.Gears or synchronizers damaged,
.Low gear oil level
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Transmission Noisy When
Moving (RWD Only) Quiet In
Neutral With Clutch Engaged .Worn rear outputshaft bearing
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Gear Rattle .Worn bearings,
.Wrong gear oil,
.Low gear oil,
.Worn gears
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Steady Ticking At Idle
(Increases With RPM) .Broken tooth on gear
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Gear Clash When Shifting
Forward Gears .Worn or broken synchronizers
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Loud Whine In Reverse .Normal condition ( 1) \
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Page 1232 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual Noise When Stepping On Clutch .Bad release bearing,
.Worn pilot bearing
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.Worn pilot bearing
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Noise When Stepping On Clutch .Bad release bearing,
.Worn pilot bearing
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Ticking Or Screeching As
Clutch Is Engaged .Faulty release bearing,
.Uneven pressure plate fingers
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Click Or Snap When Clutch
Is Engaged .Worn clutch fork,
.Worn or broken front bearing
retainer
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Transmission Shifts Hard .Clutch not releasing,
.Shift mechanism binding,
.Clutch installed backwards
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Will Not Shift Into One
Gear, Shifts Into All
Others .Bent shift fork,
.Worn detent balls
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Locked Into Gear,
Cannot Shift .Clutch adjustment,
.Worn detent balls
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Transmission Jumps Out
Of Gear .Pilot bearing worn,
.Bent shift fork,
.Worn gear teeth or face
.Excessive gear train end play
.Worn synchronizers
.Missing detent ball spring
.Shift mechanism worn or out of
adjustment
.Engine or transmission mount
bolts loose or out of adjustment
.Transmission not aligned
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Shift Lever Rattle .Worn shift lever or detents
.Worn shift forks
.Worn synchronizers sleeve
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Shift Lever Hops Under
Acceleration .Worn engine or transmission
mounts
( 1) - Most units use spur cut gears in reverse and are noisy
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POWERTRAIN
CLUTCH 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 CLUTCH TROUBLE SHOOTING CHART
Page 1233 of 1333
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CONDITION POSSIBLE CAUSE](/img/19/57332/w960_57332-1232.png "MITSUBISHI MONTERO 1991 Owners Manual \
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CONDITION POSSIBLE CAUSE")
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CONDITION POSSIBLE CAUSE CORRECTION \
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Chattering or Incorrect clutch adjustment Adjust clutch
Grabbing
Oil, grease or glaze on Disassemble and clean
facings or replace
Loose "U" joint flange See DRIVE AXLES
article
Worn input shaft spline Replace input shaft
Binding pressure plate Replace pressure plate
Binding release lever See CLUTCH article
Binding clutch disc hub Replace clutch disc
Unequal pressure plate Replace worn/misaligned
contact components
Loose/bent clutch disc Replace clutch disc
Incorrect transmission Realign transmission
alignment
Worn pressure plate, disc Replace damaged
or flywheel components
Broken or weak pressure Replace pressure
springs plate
Sticking clutch pedal Lubricate clutch pedal
& linkage
Incorrect clutch disc Replace clutch disc
facing
Engine loose in chassis Tighten all mounting
bolts
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Failure to Oil or grease on clutch Clean or replace clutch
Release facings clutch disc
Incorrect release lever or See CLUTCH article
pedal adjustment
Worn or broken clutch Replace clutch disc
facings
Bent clutch disc or Replace damaged
pressure plate components
Clutch disc hub binding on Clean or replace clutch
input shaft disc and/or input shaft
Binding pilot bearing Replace pilot bearing
Sticking release bearing Replace release bearing
sleeve and/or sleeve
Binding clutch cable See CLUTCH article
Page 1234 of 1333
Defective clutch master Replace master cylinder
Defective clutch slave Replace slave cylinder
Air in hydraulic system Bleed hydraulic system
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Rattling Weak or broken release Replace spring and
lever spring check alignment
Damaged pressure plate Replace pressure plate
Broken clutch return spring Replace return spring
Worn splines on clutch disc Replace clutch disc
or input shaft and/or input shaft
Worn clutch release bearing Replace release bearing
Dry or worn pilot bearing Lubricate or replace
pilot bearing
Unequal release lever Align or replace
contact release lever
Incorrect pedal free play Adjust free play
Warped or damaged clutch Replace damaged
disc components
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Slipping Pressure springs worn or Release pressure plate
Oily, greasy or worn Clean or replace clutch
facings disc
Incorrect clutch alignment Realign clutch assembly
Warped clutch disc or Replace damaged
pressure plate components
Binding release levers or Lubricate and/or
clutch pedal replace release
components
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Squeaking Worn or damaged release Replace release bearing
Dry or worn pilot or Lubricate or replace
release bearing assembly
Pilot bearing turning in Replace pilot bearing
crankshaft and/or crankshaft
Worn input shaft bearing Replace bearing and
seal
Incorrect transmission Realign transmission
alignment
Dry release fork between Lubricate release fork
pivot and pivot
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Heavy and/or Sticking release bearing Replace release bearing
Stiff Pedal sleeve and/or sleeve
Page 1235 of 1333
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.
Page 1238 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual \
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Knocking or Clunking
Differe](/img/19/57332/w960_57332-1237.png "MITSUBISHI MONTERO 1991 Owners Manual \
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Knocking or Clunking
Differe")
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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