MITSUBISHI MONTERO 1991 Service Manual
Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 1171 of 1333
REMOVAL
1) Disconnect negative battery cable. Remove front exhaust
pipe. On Montero, remove transfer case shift lever knob, dust boot and
retainer plate or console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
and remove. Disconnect all external solenoid and switch connections.
3) Disconnect speedometer cable and control cables at
transmission. Remove starter and bellhousing cover. Place reference
mark on torque converter and drive plate for reassembly reference.
Remove torque converter bolts.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
INSTALLATION
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Tighten mount bolts with weight of engine and transmission on mounts.
Ensure reference marks on drive shaft(s) and torque converter-to-drive\
plate align.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. Adjust all control cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Applications Ft. Lbs. (N.m)
FWD Models
Torque Converter-To-Drive Plate Bolt
Precis ....................................... 53-55 (72-76)
All Others ................................... 34-38 (46-52)
Transaxle-To-Engine Block Bolt
Mirage
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
12-mm Bolt ................................. 31-40 (42-54)
Eclipse & Galant
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
Precis
8-mm Bolt .................................. 22-25 (30-34)
10-mm Bolt ................................. 31-40 (42-54)
3000GT
Upper Coupling Bolts ............................. 54 (73)
Lower Coupling Bolts ............................. 65 (88)
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RWD Models
Torque Converter-To-Drive Plate Bolt
Montero ...................................... 25-30 (34-41)
Pickup ....................................... 33-38 (45-52)
Transmission-To-Engine Block Bolt
Montero
10x40-mm Bolt .............................. 22-30 (30-41)
12x40-mm Bolt .............................. 47-61 (64-83)
12x55-mm Bolt .............................. 58-72 (79-98)
Pickup
10x16-mm Bolt .............................. 22-30 (30-41)
10x50-mm Bolt .............................. 31-40 (42-54)
10x70-mm Bolt .............................. 31-40 (42-54)
(1) - Tighten to 84-108 INCH lbs. (10-12 N.m).
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\003
TR AN SM IS SIO N S ER VIC IN G - A /T
1991 M it s u bis h i M onte ro
1991 TRANSMISSION SERVICING
Automatic Transmission
Mitsubishi: Eclipse, Galant, Mirage,
Montero, Pickup, Precis, 3000GT
IDENTIFICATION
MITSUBISHI AUTOMATIC TRANSMISSION APPLICATIONS \
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Model Transmission/Transaxle
Eclipse
1.8 & 2.0L ........................... Model F4A22 Transaxle
2.0L Turbo ........................... Model F4A33 Transaxle
All-Wheel Drive (AWD) ................ Model W4A33 Transaxle
Galant
AWD .................................. Model W4A32 Transaxle
DOHC ................................. Model F4A22 Transaxle
SOHC ........................ Model KM175 or F4A22 Transaxle
Mirage
1.5L ................................. Model F3A21 Transaxle
1.6L ................................. Model F4A21 Transaxle
Montero ............................ Model V4AW2 Transmission
Pickup ............................. Model R4AC1 Transmission
Precis ................................ Model KM176 Transaxle
3000GT ................................ Model F4A33 Transaxle
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LUBRICATION
TRANSAXLE/TRANSMISSION SERVICE INTERVALS
Check fluid level every 12 months or 15,000 miles. Change
fluid and filter every 30,000 miles. If vehicle is operated under
severe condition, change fluid more often. If severe darkening of
fluid and strong odor are noted, bands should also be adjusted (if
equipped).
TRANSFER CASE SERVICE INTERVALS
On 4WD and AWD models, change transfer case fluid every 30,
000 miles.
CHECKING FLUID LEVEL
TRANSAXLE/TRANSMISSION
1) Park vehicle on level area. Ensure oil is at normal
operating temperature, parking brake is engaged, and engine is at
idle. Move gear selector through each position, stopping briefly in
each position.
2) Place gear selector in Neutral, and clean area around
dipstick tube. Ensure fluid level is between lower and upper marks,
but never over upper mark, in HOT range. Add or drain fluid if
necessary.
Page 1174 of 1333
CAUTION: If severe darkening of fluid and strong odor are noted,
change fluid and filter, and adjust bands.
TRANSFER CASE (3000GT)
Lubricant level should be approximately .5" (13 mm) below
fill hole on side of transfer case.
TRANSFER CASE (ALL OTHERS)
Lubricant level should be to bottom of fill hole on side of
transfer case.
RECOMMENDED FLUID
TRANSAXLE/TRANSMISSION
Use Chrysler Plus/Mitsubishi Plus ATF, Dexron and Dexron-II
ATF.
TRANSFER CASES
Use SAE 75W-85 gear oil with API GL-4 rating or higher.
FLUID CAPACITY
TRANSAXLE/TRANSMISSION REFILL CAPACITIES \
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Refill Dry Fill
Application Qts. (L) Qts. (L\
)
Mirage ..................... 4.8 (4.5) ............... 13.0 (12.2\
)
Eclipse
F4A22 .................... 4.2 (4.0) ................. 6.4 (6.1\
)
F4A33 & W4A33 ............ 6.4 (6.1) ................. 8.0 (7.6\
)
Galant
2WD ...................... 4.8 (4.5) ................. 6.4 (6.1\
)
AWD ...................... 4.8 (4.5) ................. 6.9 (6.5\
)
Montero .................... 5.8 (5.5) ................. 7.4 (7.0\
)
Pickup ................... 2.0 (1.9)( 1) ............... 10.2 (9.7)
Precis ..................... 4.8 (4.5) ................. 6.4 (6.1\
)
3000GT ..................... 4.8 (4.5) ................. 7.9 (7.5\
)
( 1) - Idle engine in Neutral, then add fluid to bring level between
notches at "H" mark.
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TRANSFER CASE REFILL CAPACITIES \
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Application Pts. (L)
Eclipse & Galant ............................ 1.3 (0.6)
Mirage ............................................ N/A
Montero & Pickup ............................ 4.6 (2.2)
3000GT ........................................ .6 (.3)
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DRAINING & REFILLING
NOTE: Although manufacturer recommends changing only fluid, the
oil filter/screen may also require replacement. If replacing
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oil filter/screen, note length and location of all bolts.
TRANSAXLE (EXCEPT MONTERO, PICKUP & RAM-50)
1) Remove drain plug(s), and drain fluid. See Fig. 1. Some
applications may contain a drain plug located in housing below drive
axle shaft, in oil pan. Remove oil pan. Remove oil filter/screen if
necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Ensure dipstick hole area is clean, and pour approximately 4.2
qts. (4.0L) of Dexron-II fluid into dipstick hole.
3) Operate engine at idle for 2 minutes. Shift transaxle to
each position, ending in Neutral. Add sufficient fluid to reach lower
mark. After reaching normal operating temperature, fluid should be
between upper and lower marks of HOT range on dipstick.
Fig. 1: Locating Drain Plugs
Courtesy of Mitsubishi Motor Sales of America.
TRANSMISSION (MONTERO & PICKUP)
1) Remove drain plug (if equipped) from transmission pan, an\
d
allow fluid to drain. On models without drain plug, remove oil pan
must to drain fluid. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Fill transmission, through filler tube, with 5.3 qts. (5.0L) of\
Dexron-II ATF on Montero, or 2.0 qts. (1.9L) on all others. Start
engine, and allow to idle for 2 minutes.
3) Shift transmission into each position, ending in Neutral.
Check fluid level with engine running at idle, and add sufficient
Page 1176 of 1333
fluid to bring level to lower mark of dipstick if necessary. Recheck
fluid level after transmission is at normal operating temperature.
TRANSFER CASE
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. On 3000GT, lubricant
level should be approximately .5" (13 mm) below fill hole on side of
transfer case. On all others models, lubricant level should be to
bottom of fill hole on side of transfer case.
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE CHECK (EXCEPT MONTERO & PICKUP)
1) Set parking brake. Place shift lever in Neutral position.
Attach engine tachometer. Remove line pressure port plug located above
front transaxle shaft, forward of governor pressure port plug. On
Precis, line pressure port is located below bell housing, at front of
transaxle oil pan. Using appropriate adapter, attach pressure gauge.
2) Start engine, and bring to operating temperature. With
gear selector in Drive position, bring engine speed to 2500 RPM. Pull
throttle control cable (if equipped) wide open at transaxle side.
3) Line pressure should be 98-100 psi (6.9-7.0 kg/cm
) on
Mirage, or 124-127 psi (8.7-8.9 kg/cm) on all others. If line
pressure is not to specification, proceed to LINE PRESSURE ADJUSTMENT.
LINE PRESSURE ADJUSTMENT (EXCEPT MONTERO & PICKUP)
1) Drain transaxle fluid. Remove oil pan. Disconnect throttle
control cable from throttle cam. Remove oil temperature sensor (if
equipped). Disconnect solenoid connector. On some models, it may be
necessary to push solenoid wire harness connector and grommet into
transaxle case.
2) Remove oil filter screen and plate. Noting location and
length of bolts, remove valve body. DO NOT drop internal parts. Adjust
line pressure by turning regulator valve adjusting screw.
3) Turn adjusting screw counterclockwise to increase pressure
or clockwise to decrease pressure. One complete turn of adjusting
screw changes line pressure as follows.
* 3.7 psi (.26 kg/cm
) on Mirage with F3A21 Transaxle
* 5.4 psi (.39 kg/cm) on Precis
* 54 psi (3.8 kg/cm) on all others
4) After adjustment, reverse removal procedure to install.
Refill transaxle.
LINE PRESSURE (MONTERO)
1) Remove plug from line pressure take-off port located
behind transmission shift control lever. Install Hydraulic Pressure
Meter (MD998330) with Adapter (MD998206).
2) Place vehicle on dynamometer. Apply parking brake and
start engine. With brake applied, place transmission in Drive. Note
pressure at idle. Pressure should be 74-85 psi (5.2-6.0 kg/cm
).
3) Raise engine RPM to stall speed (2100-2400 RPM). Note lin\
e
pressure. Pressure should be 156-185 psi (11.0-13.0 kg/cm
).
4) Shift transmission into Reverse with brake applied. At
idle, pressure should be 112-130 psi (7.9-9.1 kg/cm
). Raise engine
RPM to stall speed (2100-2400 RPM). Note line pressure. Pressure
should be 227-285 psi (16.0-20.0 kg/cm
). If readings are not to
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specification, use the following trouble shooting guide.
* Hydraulic Pressure High In All Ranges
Check throttle cable adjustment. If adjustment is okay, check
for throttle valve or regulator valve failure.
* Hydraulic Pressure Low In All Ranges
Check throttle cable adjustment. If adjustment is okay, check
for throttle valve, regulator valve, transmission oil pump or
overdrive clutch failure.
* Hydraulic Pressure Low In Drive Position
Check for fluid leaks in Drive hydraulic circuit. Check for
forward clutch or overdrive clutch failure.
* Hydraulic Pressure Low In Reverse Position
Check for fluid leaks in Reverse hydraulic circuit. Check for
transmission No. 3 brake failure, forward clutch failure or
overdrive clutch failure.
LINE PRESSURE (PICKUP)
1) Incorrect throttle pressure setting will cause incorrect
line pressure readings even though line pressure adjustment is
correct. Always inspect and correct throttle pressure adjustment
before adjusting line pressure.
2) Approximate adjustment, measured from valve body to inner
edge of adjusting nut, is 15/16". However, due to manufacturing
tolerances, adjustment can be varied to obtain correct line pressure.
3) Adjusting screw may be turned with an Allen wrench. One
complete turn of adjusting screw changes closed throttle line pressure
approximately 1 2/3 psi. Turn adjusting screw counterclockwise to
increase pressure or clockwise to decrease pressure.
THROTTLE PRESSURE (PICKUP)
1) Throttle pressures cannot be accurately tested. If a
malfunction exists, adjustment should be measured.
2) Insert Gauge Pin (C-3763) between throttle lever cam and
kickdown valve. Push in on tool to compress kickdown valve against its
spring.
3) As force is being exerted to compress spring, turn
throttle lever screw with Allen wrench until head of screw touches
throttle lever tang with gauge pin, and throttle valve bottoms. Ensure
adjustment is made with spring fully compressed and valve bottomed in
valve body.
KICKDOWN BAND
PICKUP
1) Locate kickdown band adjusting screw on left side of
transmission case. Loosen lock nut, and back off nut 5 turns. Ensure
adjusting screw turns freely in transmission case.
2) Using torque wrench, tighten adjusting screw to 72 INCH
lbs. (8 N.m). Back off adjusting screw 2 7/8 turns. Hold adjuster
screw in this position, and tighten lock nut to 30 ft. lbs. (41 N.m).
LOW-REVERSE BAND
PICKUP
1) Raise vehicle, drain transmission, and remove oil pan.
Loosen adjusting screw lock nut, and back off nut 5 turns. Ensure
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
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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 1180 of 1333
PICKUP
1) Ensure engine idle is adjusted correctly. Ensure throttle
lever and throttle cable bracket are not bent. Pull lightly on inner
throttle cable.
2) While in closed throttle position, measure gap between
inner cable stopper and outer cable housing. Adjust cable as necessary
to obtain a gap of .031-.059" (.79-1.50 mm). See Fig. 4 (STEP 1).
Fig. 4: Adjusting Throttle Cable (Pickup)
Courtesy of Mitsubishi Motor Sales of America.
3) While holding throttle in wide open position, pull on
inner throttle cable. Adjust bell crank as necessary to obtain a gap
of 1.46-1.50" (37.08-38.10 mm) between inner cable stopper and outer
cable. See Fig. 4 (STEP 2).
4) With throttle fully closed, recheck gap between inner
cable stopper and outer cable housing. Gap should be .031-.059" (.79-
1.50 mm). See Fig. 4 (STEP 3). While holding throttle in wide open
position, pull on inner throttle cable. Check for a gap of 1.30-1.38"
(33.02-35.05 mm).
Montero Ensure throttle lever and throttle cable bracket
are not bent. Ensure distance between inner cable stopper end and dust
cover is 0-.04" (0-1.0 mm). See Fig. 5.
Fig. 5: Adjusting Throttle Cable (Montero)
Courtesy of Mitsubishi Motor Sales of America.
SHIFT LINKAGE