transmission 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 1178 of 1333
adjusting screw turns freely in lever.
2) Using torque wrench, tighten band adjusting screw to 30
INCH lbs. (3.5 N.m). Back off adjusting screw 6 turns. Hold adjusting
screw in this position, and tighten lock nut to 25 ft. lbs. (34 N.m).
3) Reinstall oil pan using new gasket. Tighten pan bolts to
150 INCH lbs. (17 N.m). Refill with specified transmission fluid.
KICKDOWN SERVO
ECLIPSE, GALANT, MIRAGE, PRECIS & 3000GT
1) Remove all dirt and grease around kickdown servo switch.
Remove snap ring and kickdown servo switch.
2) To prevent servo piston from turning, install Adapter
(MD998915) and Kickdown Servo Wrench (MD998914) so tab of wrench
engages with notch of piston. See Fig. 2.
CAUTION: DO NOT push servo piston inward while installing adapter
and servo wrench. Install adapter in brake pressure port by
hand ONLY. DO NOT use wrench to tighten adapter.
Fig. 2: Adjusting Kickdown Servo (Except Montero & Pickup)
Courtesy of Mitsubishi Motor Sales of America.
3) Loosen lock nut to "V" channel of adjuster rod. See
Fig. 2 . Tighten inner section of Kickdown Service Adjustment Assembly
(MD998916) until it contacts lock nut.
4) Install outer section of kickdown service adjustment
assembly on lock nut. Rotate outer section to left and inner section
to right to contact lock nut with inner section.
5) Using an INCH lb. torque wrench on inner section, tighten
inner section to 86 INCH lbs. (9.8 N.m), and then loosen inner
section. Tighten inner section to 43 INCH lbs. (4.9 N.m).
CAUTION: Before tightening lock nut with torque wrench, tighten it
by hand until it contacts piston. If torque wrench is used
Page 1179 of 1333
initially, lock nut and adjustment rod may rotate together.
6) Back off outer section 2-2 3/4 turns. Rotate outer section
to right and inner section to left until inner section is free of lock
nut. Tighten lock nut by hand until it contacts piston. Using torque
wrench, tighten lock nut to 18-23 ft. lbs. (25-32 N.m).
7) Remove adapter and kickdown servo wrench. Install new "O"
ring in groove around switch. Install switch and snap ring.
TRANSMISSION THROTTLE CONTROL
MIRAGE
1) On all other models, ensure throttle lever is in curb idle
position. Engine must be at normal operating temperature.
2) On all models, raise cover "B" of throttle cable upward to
expose nipple. See Fig. 3. Loosen lower cable bracket mounting bolt.
Move lower cable bracket until distance between nipple and top of
cover "A" on throttle cable is .02-.06" (.5-1.5 mm).
3) Tighten lower cable bracket mounting bolt to 108-126 INCH
lbs. (12-14 N.m). With throttle lever in wide open throttle position,
pull cable upward to ensure some cable free play exists.
Fig. 3: Adjusting Throttle Cable (Mirage)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: On Pickup, always adjust throttle control cable
whenever idle is adjusted.
Page 1181 of 1333
MONTERO
Loosen swivel nut on transmission control rod. See Fig. 6.
Ensure shift and transmission levers are both in Neutral. Tighten
swivel nut.
Fig. 6: Adjusting Shift Linkage (Montero)
Courtesy of Mitsubishi Motor Sales of America.
EXCEPT MONTERO
Adjust shift cable at transaxle/transmission end of cable.
Place shift lever Neutral. Ensure shift lever and neutral safety
switch are in Neutral position. If cable was replaced, ensure toothed
washer is installed (if equipped). See Fig. 7. Turn adjuster at cable
end so it fits into manual lever on transaxle/transmission, and no
slack exists in cable. See Fig. 7.
Fig. 7: Adjusting Shift Cable (Except Montero)
Courtesy of Mitsubishi Motor Sales of America.
Page 1184 of 1333
1) Neutral safety switch is located under shift lever
console. Set shift lever so pin at end of rod is positioned correctly.
See Fig. 10 .
2) Using an ohmmeter, check continuity between Black/Yellow
wires when neutral safety switch is moved back and forth. Mark
bracket.
3) Tighten neutral safety switch mounting screws so clearance
between switch and selector lever is .1" (2.5 mm).
Fig. 10: Adjusting Neutral Safety Switch (Montero)
Courtesy of Mitsubishi Motor Sales of America.
PICKUP
Neutral safety switch is part of transmission-mounted neutral
safety/back-up light switch assembly, and is non-adjustable.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)
Drain Plug
Transaxle/Transmission
Montero ................................. 13-17 (18-23)
All Other Models ........................ 22-25 (30-35)
Transfer Case ............................ 22-25 (30-35)
INCH Lbs. (N.m)
Oil Filter/Screen Bolt
Except Montero & Pickup ................ 48-60 (5.4-6.8)
Montero ................................ 43-52 (4.9-5.9)
Pickup ........................................ 35 (4.0)
Oil Pan Bolt
Eclipse & Montero ...................... 36-42 (4.0-4.8)
Pickup ........................................ 156 (18)
All Other Models ..................... 84-108 (9.5-12.2)
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\003TR AN SM IS SIO N S ER VIC IN G - M /T
1991 M it s u bis h i M onte ro
1990-91 Manual Transmission Servicing
Eclipse, Galant, Mirage, Montero, Pickup, Precis, Sigma
IDENTIFICATION
1990 MANUAL TRANSMISSION APPLICATIONS TABLE \
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Model Transmission
Eclipse
1.8L SOHC ..... 5-Speed - Model F5M22 Transaxle
1.8L DOHC ..... 5-Speed - Model F5M22 Transaxle
2.0L DOHC
Turbo ........ 5-Speed - Model F5M33 Transaxle
Galant ......... 5-Speed - Model KM206 Transaxle
Mirage
1.5L ......... 5-Speed - Model KM201 Transaxle
1.6L ......... 5-Speed - Model KM210 Transaxle
Montero
2.6L ................... 5-Speed - Model KM145
3.0L ................... 5-Speed - Model V5MT1
Pickup
2WD .................... 5-Speed - Model KM132
4WD .................... 5-Speed - Model KM145
Precis ......... 4-Speed - Model KM161 Transaxle
5-Speed - Model KM163 Transaxle
Sigma .......... 5-Speed - Model KM210 Transaxle
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1991 MANUAL TRANSMISSION APPLICATIONS TABLE \
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Model Transmission
Eclipse
2.0L ............... 5-Speed Transaxle (F5M22)
2.0L (Turbo) ....... 5-Speed Transaxle (F5M33)
Galant
2WD ................ 5-Speed Transaxle (F5M22)
AWD
DOHC ............. 5-Speed Transaxle (W5M31)
DOHC (Turbo) ..... 5-Speed Transaxle (W5M33)
Mirage
1.5L ............... 4-Speed Transaxle (F4M21)
5-Speed Transaxle (F5M21)
1.6L ............... 5-Speed Transaxle (F5M22)
Montero ........... 5-Speed Transmission (V5MT1)
Pickup
2WD ............. 5-Speed Transmission (R5M21)
4WD ............. 5-Speed Transmission (V5MT1)
Precis ............... 4-Speed Transaxle (KM200)
5-Speed Transaxle (KM201)
3000GT
2WD ................ 5-Speed Transaxle (F5M33)
AWD ................ 5-Speed Transaxle (W5MG1)
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LUBRICATION SERVICE INTERVALS
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Check transaxle/transmission and transfer case fluid level
every 30,000 miles. Change fluid at 30,000 miles if operated under
severe service conditions.
CHECKING FLUID LEVEL
TRANSAXLE/TRANSMISSION
Lubricant level is checked at fill hole on side of transaxle
or transmission. Lubricant must be at bottom of fill hole.
TRANSFER CASE
Transfer case contains separate drain and fill plugs.
Lubricant must reach to bottom of fill hole.
On 3000GT models, transfer case contains separate drain and
fill plugs. Lubricant should be .5" (13 mm) from bottom of fill hole.
RECOMMENDED FLUID
Use API GL-4 or GL-5 SAE 75W-85 gear oil.
FLUID CAPACITY SPECS TABLE
TRANSMISSION REFILL CAPACITIES TABLE \
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Application Pts. (L)
Eclipse
F5M22 .............................. 3.8 (1.8)
F5M33 .............................. 4.7 (2.2)
Galant ............................... 3.8 (1.8)
Mirage
KM201 .............................. 3.8 (1.8)
KM210 .............................. 4.4 (2.0)
Montero
2.6L ............................... 4.7 (2.2)
3.0L ............................... 5.3 (2.6)
Pickup
2WD ................................ 4.9 (2.4)
4WD ................................ 4.7 (2.2)
Precis ............................... 4.4 (2.0)
Sigma ................................ 5.2 (2.5)
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1991 TRANSMISSION REFILL CAPACITIES \
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Application Pts. (L)
Mirage (1.5L)
F4M21 ................................... 3.6 (1.7)
F5M21 ................................... 3.8 (1.8)
Eclipse, Galant (2WD) & Mirage (1.6L) ..... 3.8 (1.8)
Eclipse (Turbo) & 3000GT (2WD) ............ 4.9 (2.3)
Galant (AWD) .............................. 4.9 (2.3)
Montero & Pickup .......................... 5.2 (2.5)
Pickup .................................... 4.9 (2.3)
Pickup .................................... 4.6 (2.2)
Precis
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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![MITSUBISHI MONTERO 1991 Owners Manual Noise When Stepping On Clutch .Bad release bearing,
.Worn pilot bearing
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\](/img/19/57332/w960_57332-1231.png "MITSUBISHI MONTERO 1991 Owners Manual Noise When Stepping On Clutch .Bad release bearing,
.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
![MITSUBISHI MONTERO 1991 Owners Manual \
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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