MITSUBISHI MONTERO 1991 Service Manual

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.

SHIFT LEVER SLEEVE
NOTE: Pickup does not have shift lever sleeve.
EXCEPT PICKUP
To adjust shift lever sleeve, remove shift handle on top of
shift lever. With lever in Neutral, turn sleeve so distance between
sleeve and lever end is .60-.63" (15.2-16.0 mm). See Fig. 8. Ensure
beveled side of sleeve faces toward push button (if equipped).
Fig. 8: Adjusting Shift Lever Sleeve (Except Pickup)
Courtesy of Mitsubishi Motor Sales of America.
NEUTRAL SAFETY SWITCH
EXCEPT MONTERO & PICKUP
1) Place shift and manual control levers in Neutral. For
adjustment, turn switch body in order to align small end of manual
control lever with corresponding flange on switch body. Tighten switch
mounting bolts to 84-108 INCH lbs. (10-12 N.m).
CAUTION: DO NOT drop switch body.
2) Loosen nut at end of transaxle control cable, and lightly
pull in direction of switch. Tighten nut to 84-120 INCH lbs. (10-14 N.
m). See Fig. 9.
3) Ensure selector lever is in Neutral. Ensure lever
functions correctly at transaxle, in range corresponding to that
indicated by selector lever.

Fig. 9: Adjusting Inhibitor (Neutral Safety) Switch (Except
Montero, Pickup)
Courtesy of Mitsubishi Motor Sales of America.
MONTERO

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

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

KM200 ................................... 3.6 (1.7)
KM201 ................................... 3.8 (1.8)
3000GT (AWD) .............................. 5.0 (2.4)









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TRANSFER CASE REFILL CAPACITIES TABLE








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Application Pts. (L)
Eclipse .............................. 1.5 (0.7)
Montero & Pickup ..................... 4.7 (2.2)
Eclipse .............................. 1.5 (0.7)
Galant ............................... 1.3 (0.6)
Montero & Pickup ..................... 4.6 (2.2)
3000GT ................................. .6 (.3)









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SELECT CABLE ADJUST
GALANT, MIRAGE & SIGMA
1) With transaxle select lever in Neutral, move gearshift
lever into 4th gear. It may be necessary to depress clutch pedal.
2) Loosen selector cable adjuster nuts (inside of vehicle).
See Fig. 2 . With select lever in Neutral, adjust select cable end
until eye fits easily over select lever pin. Tighten adjuster nuts.
SHIFT CABLE & GEARSHIFT LEVER ADJUST
GALANT, MIRAGE & SIGMA
1) With transaxle select lever in Neutral, move gearshift
lever into 4th gear. It may be necessary to depress clutch pedal.
2) Loosen shift cable adjuster nuts (inside of vehicle) and
disconnect cable end from shift lever pin. Tilt gearshift lever into
4th gear position until it touches stopper. See Fig. 3. Hold lever in
this position and adjust shift lever cable so cable aligns with shift
lever pin.
3) Move shift lever between 3rd, Neutral and 4th gear
positions. Shift lever-to-stopper clearances should be equal on both
sides of lever. See Fig. 3. If clearances "A" and "B" are not equal,
readjust shift cable. Road test vehicle to ensure proper adjustment
and smooth shifting.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Drain Plug & Filler Plug
Eclipse, Galant & Mirage ............. 22-25 (30-34)
Montero, Pickup ..................... 22-25 (30-34)
4WD 3.0L ............................ 40-61 (54-83)
Precis & 3000GT ................................ ( 1)
( 1) - Information is not available from manufacturer.









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Fig. 1: Typical Transaxle Control Cable
Courtesy of Chrysler Motors.
Fig. 2: Adjusting Select Cable
Courtesy of Chrysler Motors.

Fig. 3: Adjusting Shift Cable
Courtesy of Chrysler Motors.

\003
TR O UBLE S H O OTIN G - B ASIC P R O CED URES

1991 M it s u bis h i M onte ro
GENERAL TROUBLE SHOOTING
* PLEASE READ THIS FIRST *
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.
ACCESSORIES & ELECTRICAL
CHARGING SYSTEM 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 CHARGING SYSTEM TROUBLE SHOOTING CHART









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CONDITION POSSIBLE CAUSE CORRECTION








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Vehicle Will Not Dead battery Check battery cells,
Start alternator belt
tension and alternator
output
Loose or corroded battery Check all charging
connections system connections
Ignition circuit or switch Check and replace as
malfunction necessary









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Alternator Light Loose or worn alternator Check alternator drive
Stays On With drive belt tension and
Engine Running condition, See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Loose alternator wiring Check all charging
connections system connections
Short in alternator light See Indicator Warning
wiring Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
Defective alternator stator See Bench Tests in
or diodes ALTERNATOR article
Defective regulator See Regulator Check in