oil MITSUBISHI MONTERO 1991 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 1154 of 1333
Fig. 2: Detection Switch Testing Locations (Montero)
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
Removal
1) Remove negative battery cable. Remove transfer case skid
plate (if equipped). Scribe alignment marks and remove both drive
shafts. Drain oil from transfer case. Disconnect wiring harness from
back-up light switch, all 4WD switches and any other electrical
connectors (if equipped).
2) Disconnect speedometer cable from drive. Unclip cable from
case. Place transfer case shifter in "2H" position and transmission in
Neutral. Remove 6 bolts holding control lever assembly. Remove control
lever assembly and gasket.
3) Remove select plunger bore plug at right side of case.
Remove select spring and plunger. Remove change shifter spring pin.
Remove change shifter. Remove transfer case mount. Remove 4 bolts and
2 nuts holding transfer case to adapter. Remove transfer case from
vehicle.
Page 1155 of 1333
Installation
1) Position transmission shifter in Neutral and transfer case
lever in "2H" position. Install neutral return plungers and springs in
holes on top of adapter. Tighten plug until it is flush with adapter
surface. Cover plug threads with sealant.
2) Coat inside of change shifter with grease. Ensure change
shifter pin protrudes 1/8" above change shifter when installed. Mount
detent plunger spring and install plug (if equipped). To complete
installation, reverse removal procedure. Fill transfer case with API
GL-4 or higher 75W-90 or 75W-85W gear oil.
Fig. 3: Exploded View Of Transfer Case (Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
Page 1157 of 1333
2) Remove 2 seal plugs. Remove 2 poppet springs and steel
balls. Shift transfer case to "4WD" and pull high-low shift rail out,
in rear cover direction. Remove interlock plunger. Remove pulse
generator (if equipped), front output shaft cover and pulse rotor (if\
equipped). Remove snap ring from rear bearing on output shaft. Remove
chain cover, oil guide and side cover. Remove countershaft locking
plate. Remove countershaft.
3) Remove countergear, 2 thrust washers, 2 needle bearings
and spacer through side cover opening. Remove snap ring, spring
retainers and spring from 2WD-4WD shift rail. Remove front output
shaft, rear output shaft and chain as assembly.
4) Remove 2WD-4WD shift fork and distance piece. Drive out
2WD-4WD shift rail spring pin. Remove 2WD-4WD shift rail and lug.
Remove high-low shift fork and high-low synchronizer sleeve. Remove
needle bearing and snap ring from input gear. Remove input gear
assembly.
5) If either control shaft or input gear oil seals are to be
replaced, drive out roll pin from transmission control change shifter.
Separate transfer case from adapter. See Fig. 3.
Disassembly (Montero)
1) Remove dynamic damper, 5 detection switches and 3 steel
balls. Remove poppet plug, spring and steel ball. Remove speedometer
gear assembly. Remove output shaft rear cover, spacers, dust seal
guard and oil seals. Front output shaft cover, wave spring and spacer
(if equipped).
2) Remove high-low shift rail plug and high-low shift fork
spring pin. Shift transfer case to "4WD". Remove rear cover and high-
low shift rail. Remove interlock plunger. Remove rear output shaft
(viscous coupling) assembly and center differential assembly. Remove
2WD-4WD synchronizer assembly, chain and front output shaft from
transmission as a unit. With White paint make match marks in grooves
of 2WD-4WD synchronizer in 3 places. With White paint make match marks
on spline projections of 2WD-4WD synchronizer sleeve in 3 places.
Refer to match marks during reassembly.
3) Remove snap ring, spring seat, spring, 2WD-4WD shift fork
and 2WD-4WD synchronizer sleeve. Remove differential lock hub, oil dam
cover and bearing retainer. Remove side cover and gasket. Remove
transfer counter gear shaft, transfer counter gear, thrust washer,
needle bearings and spacer. Remove transfer drive shaft assembly.
Remove high-low shift fork assembly and clutch sleeve. Remove transfer
input gear assembly.
4) Remove 2WD-4WD shift lug spring pin, spring, spring
retainer 2WD-4WD shift lug and shift rail. Remove input gear oil seal,
baffle plate, dust seal guard and front output shaft oil seal. See
Fig. 4 .
COMPONENT DISASSEMBLY & REASSEMBLY
OUTPUT SHAFT ASSEMBLY (MONTERO)
Disassembly & Reassembly (Rear Shaft)
Remove snap ring and press ball bearing off without putting
pressure on vicious coupling. Remove viscous coupling. To install,
reverse removal procedure. When installing new snap ring, select
thickest ring that will fit into groove. Acceptable clearance is 0-.
003" (0-.08 mm).
Disassembly & Reassembly (Front Shaft)
Remove front bearing. Remove rear bearing. To install reverse
removal procedure.
Page 1161 of 1333
Disassembly
Remove snap ring, 2WD-4WD synchronizer hub and synchronizer
spring. Remove outer synchronizer ring, synchronizer cone and inner
synchronizer ring. Remove drive sprocket and needle bearing from front
drive pinion. Inspect inner and outer synchronizer rings and cone for
excessive wear. Install inner and outer synchronizer rings and cone
onto drive sprocket. Measure distance between drive sprocket and outer
synchronizer. If distance is less than .0118" (.300 mm) replace
synchronizer parts as a set.
Reassembly
Install drive sprocket and needle bearing onto front drive
pinion. Apply transfer case gear oil to contacting surfaces of inner
and outer synchronizer rings and synchronizer cone. Install inner and
outer synchronizer rings and synchronizer cone. Install synchronizer
spring, 2WD-4WD synchronizer hub and snap ring to complete assembly.
When installing new snap ring, select thickest ring that will fit into
groove. Acceptable snap ring clearance is 0-.003" (0-.080 mm).
Fig. 8: Exploded View Of 2WD-4WD Synchronizer (Montero)
Courtesy of Mitsubishi Motor Sales of America.
TRANSFER CASE REASSEMBLY
NOTE: ALWAYS replace all gaskets, oil seals, snap rings and spring
pins with new parts. Coat both sides of gaskets and bolt
threads with sealant. Lubricate all sliding and rotating
parts with transfer case gear oil before assembling.
Reassembly (Ram-50)
Page 1162 of 1333
1) Install input gear and front output shaft oil seals into
transfer case housing. Pack grease between lips of seals and press
seal circumference uniformly.
2) Install input gear assembly in transfer case. See Figs. 3
and 6. Input gear assembly snap ring is available in selective
thicknesses. Use thickest snap ring that will fit into input shaft
groove. Allowed snap ring clearance is 0-.0024" (0-.060 mm).
3) Insert needle bearing onto rear output shaft assembly.
Install high-low synchronizer sleeve and shift fork. Install 2WD-4WD
shift fork. Engage chain securely on front and rear output shaft
sprockets. Assemble 2WD-4WD synchronizer sleeve with 2WD-4WD shift
fork. Install assembly over 2WD-4WD shift rail. Install front and rear
output shafts with chain as an assembly.
4) Install 2WD-4WD shift lug, distance piece, 2WD-4WD shift
rail and spring pin. Ensure slit in spring pin is in line with 2WD-4WD
shift rail. Install 2 spring retainers with spring on 2WD-4WD shift
rail. Install snap ring to end of 2WD-4WD shift rail. See Fig. 3.
5) Insert 2 needle bearings and spacer into countergear.
Install one thrust washer at each end of countergear. Ensure tab on
thrust washers fits into groove of transfer case. Install countergear
shaft assembly with "O" ring.
6) Install side cover and gasket. Install oil guide. Apply
sealant to both sides of gasket and install gasket and chain cover.
Ensure oil guide end fits into chain cover opening. Fit snap ring into
groove of rear bearing on rear output shaft. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
7) Install interlock plunger. Shift 2WD-4WD shift rail to 4WD
position. Install high-low shift rail through high-low shift fork in
case. Install 2 poppet balls and springs. Install seal plugs. When
installing poppet springs, smaller end must be toward ball.
8) On models with pulse generator, install pulse rotor, wave
spring and spacer. Measure protrusion "A" of front output shaft rear
bearing and recess "B" of cover and calculate clearance. See Fig. 9.
If clearance is greater than .079" (2.0 mm), select and install spacer\
to bring clearance within specification. If clearance is less than .
079" (2.0 mm), use wave spring alone. Apply sealant to both sides of
gasket and install gasket and cover. Install pulse generator (if
equipped).
9) On all models, align high-low shift fork and shift rail
spring holes and drive in roll pin with punch. Roll pin should be
installed with slit on center line of shift rail. Install wave spring
on rear of rear output shaft bearing. Apply sealant to both sides of
rear cover gasket. Install gasket and cover.
10) Check output shaft end play. Measure protrusion "A" of
rear output shaft rear bearing and recess "B" of cover and calculate
clearance. Ensure end play is 0-.004" (0-.10 mm). Apply sealant to
both sides of gasket and install gasket and cover. See Fig. 9.
11) Install speedometer sleeve assembly in rear cover. Align
match mark on speedometer sleeve assembly in rear cover. See Fig. 10.
Align match mark on speedometer sleeve with mark on case according to
number of teeth on speedometer driven gear. Install speedometer driven
gear sleeve clamp and tighten bolt to specification. Install both 4WD
indicator light switches with steel balls. See TORQUE SPECIFICATIONS.
Page 1164 of 1333
Fig. 10: Aligning Speedometer Sleeve
Courtesy of Mitsubishi Motor Sales of America.
Reassembly (Montero)
1) Install input gear and front output shaft oil seals into
transfer case housing. Install transfer input gear assembly baffle
plate and input gear seal. Pack grease between lips of seals and press
seal circumference uniformly.
2) Install 2WD-4WD shift lug into transfer case. Install
spring retainer and spring to shift rail and install into shift lug.
Press on shift rail to align spring pin holes in shift rail and shift
lug. While holding shift rail, tap spring pin into place with slit
facing center of shift rail.
3) Install transfer input gear assembly and snap ring. Select
thickest snap ring that will fit into groove. Allowed snap ring
clearance is 0-.0024" (0-.060 mm). Insert needle bearing onto transfer\
drive shaft assembly. Install high-low synchronizer sleeve and shift
fork assembly. Install transfer drive shaft assembly.
4) Install transfer countergear shaft thrust washers, needle
bearings, bearing spacer and transfer countergear. Install one thrust
washer at each end of transfer countergear. Ensure tab on thrust
washers fits into groove of transfer case. Install counter gear shaft
from transmission case side so lock plate groove is aligned with lock
plate. Install lock plate. Install side cover and gasket.
5) Install bearing retainer. If reusing bearing retainer
bolts, apply Locking Adhesive (3M 4170 Stud Lock) to threads. Install
oil dam cover. Install differential lock hub, snap ring, steel ball
and sleeve. Select thickest snap ring that will fit into groove.
Allowed snap ring clearance is 0-.003" (0-.08 mm). Install 2WD-4WD
synchronizer sleeve, 2WD-4WD shift fork, spring, spring seat and 2WD-
Page 1166 of 1333
mm) to clearance measured and install spacer of similar thickness.
Install rear output shaft oil seal (apply grease to lip of seal).
Install rear cover oil seal (apply grease to lip of seal).
11) Before installing rear cover, snap ring and spacer
thicknesses must be determined. Measure protrusion of rear output
shaft bearing. Measure inset of both stages of cover. Subtract inset
recess from rear bearing protrusion. Select a snap ring which adjusts
difference between inset recess and rear bearing protrusion, and
spacer thickness to 0-.004" (0-0.10 mm). Evenly apply sealant to rear
cover and install cover. Tighten bolts to specification. Refer to the
TORQUE SPECIFICATIONS table.
12) Install speedometer gear, ensuring mating marks match
according to number of gear teeth. Install speedometer gear sleeve
clamp and tighten bolt to specification. See Fig. 10.
13) Apply sealant to poppet plug threads. Install poppet
steel balls, springs and poppet plugs and tighten to specification.
Install detection switches, steel balls and gaskets. See Fig. 12.
Install dynamic damper and tighten bolts to specification.
Fig. 12: Installation Of Detection Switches (Montero)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
Page 1167 of 1333
![MITSUBISHI MONTERO 1991 Service Manual TORQUE SPECIFICATIONS TABLE \
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TORQUE SPECIFICATIONS TABLE \
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Application Ft. Lbs. (N.m)
Adapter-To-Transfer Bearing Retainer ......... (1) 14 (19)
Case Nuts & Bolts .......................... 22-31 (30-42)
Center Differential Case Bolts ................... 48 (65)
Chain Cover Bolt ........................... 22-31 (30-42)
Detection Switch ............................. ( 1) 27 (36)
Drain Plug ................................. 22-26 (30-35)
Dynamic Damper ................................... 52 (70)
High-Low Shift Rail Plug ..................... ( 1) 24 (33)
Interlock Plunger Plug ................. ( 1) 22-26 (30-35)
Lock Plate Bolts ........................... 11-16 (15-22)
Oil Dam Cover ................................ ( 1) 14 (19)
Oil Filler Plug ............................ 22-26 (30-35)
Output Shaft Cover Bolt .................... 11-16 (15-22)
Poppet Plug .................................. ( 1) 27 (36)
Pulse Rotor Bolt ....................... ( 2) 11-16 (15-22)
Rear Cover Bolt ............................ 11-16 (15-22)
Rear Output Shaft Lock Nut ............... 74-96 (100-130)
Seal Plug .............................. ( 2) 22-31 (30-42)
Speedometer Sleeve Clamp Bolt .............. 11-16 (15-22)
4WD Indicator Light Switch ................... ( 2) 22 (33)
INCH Lbs. (N.m)
Pulse Generator Bolt .................. ( 2) 89-106 (10-12)
Side Cover Bolt ............................. 71-89 (8-10)
( 1) - Montero.
( 2) - Ram-50.
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WIRING DIAGRAMS
Page 1170 of 1333
\003
TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - A /T
1991 M it s u bis h i M onte ro
1991 92 TRANSMISSION SERVICING
Transmission Removal & Installation
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
MANUAL
NOTE: For manual transmission/transaxle replacement procedures,
see appropriate article in CLUTCHES.
AUTOMATIC FWD MODELS
REMOVAL
1) Remove battery and battery tray. On 3000GT, remove
undercover(s). On Eclipse turbo, drain and remove intercooler. On all
models, remove air cleaner and case. Raise and support vehicle. Remove
wheels. Disconnect control cables at transaxle. Drain transaxle fluid.
2) On Mirage 1.6L, disconnect tension rod. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) On Galant models with electronically controlled
suspension, remove air compressor and bracket. Disconnect front height
sensor rod at lower control arm.
4) On all models, remove upper transaxle-to-engine bolts.
Remove engine undercover (if equipped). On all models, remove drive
axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Separate
lower control arms from struts for access to axle shafts (if
necessary).
5) Remove front exhaust pipe (if necessary). On Eclipse 4WD,\
Galant 4WD and 3000GT, remove right member and gusset. On 4WD models,
separate transfer assembly from transaxle. Reference mark transfer
assembly-to-drive shaft and remove transfer assembly.
6) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
7) Support transaxle with jack. Remove transaxle mounts
bolts, mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
INSTALLATION
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. Adjust all control cables.
RWD MODELS
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)