torque MITSUBISHI MONTERO 1991 Owner's Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 51 of 1333
Removal
1) Remove shaft nut while holding armature plate with clutch
disk wrench. Install clutch disk puller and remove clutch plate.
Remove snap ring from center of clutch pulley.
2) Use a universal gear puller to remove clutch pulley. See
Fig. 3 .Remove screw securing clutch coil ground lead. Use puller to
remove clutch coil.
Installation
1) To install clutch coil, reverse removal procedure.
Carefully press clutch coil into place. Ensure that coil lead and
connector are positioned on same side as removed coil.
2) Install a NEW clutch pulley snap ring, being careful not
to damage shaft seal. Press clutch plate into place. Install shaft nut
and torque to 0.9-1.4 INCH lbs. (0.10-.12 N.m).
3) Use a feeler gauge to check clutch plate-to-pulley
clearance. Clearance should be .012-.024" (0.3-0.6 mm). If clearance
is too large, remove shaft nut and again press in clutch plate. If
clearance is too small, increase gap by pulling up clutch plate. Do
not remove shaft nut.
Fig. 3: Explode View of Compressor Clutch (Calsonic V5)
Courtesy of Nissan Motor Co. U.S.A.
DIESEL KIKI ROTARY VANE CLUTCH R & I
Page 203 of 1333
hardware.
Attaching hardware
not functioning ........ A ... Require repair or replacement
of hardware.
Leaking ................. B .. Require repair or replacement.
Linkage bent (rear
load valves) ........... A ... Require repair or replacement
of linkage.
Linkage broken (rear
load valves) ........... A ... Require repair or replacement
of linkage.
Linkage disconnected
(rear load valves) ..... C ... Require repair or replacement
of linkage.
Pressure out of
specification .......... B ...... Require adjustment. If not
possible, require replacement.
Seized .................. A ............ Require replacement.
Sticking ................ A .. Require repair or replacement.
Terminal burned,
affecting performance .. A ........... (1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead burned ........ A .. Require repair or replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or replacement
of part.
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WHEEL ATTACHING HARDWARE
For conditions noted below, also check condition of wheel
stud holes.
CAUTION: Proper lug nut torque is essential. Follow manufacturer's
torque specifications and tightening sequence. DO NOT
lubricate threads unless specified by the vehicle
manufacturer.
WHEEL ATTACHING HARDWARE INSPECTION
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Condition Code Procedure
Bent .................... A ............ Require replacement.
Broken .................. A ........ ( 1) Require replacement.
Loose ................... B ... Require repair or replacement
of affected component.
Page 214 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
e
rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic li](/img/19/57332/w960_57332-213.png "MITSUBISHI MONTERO 1991 Owners Manual Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
e
rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic li")
Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
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rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic line to prevent spillage of
brake fluid.
2) Remove hose clip from brake hose mount. Disconnect brake
hose from caliper. Remove upper and lower caliper-to-steering knuckle
bolts. Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See the TORQUE SPECIFICATIONS table. Bleed brake
system. See BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal (Montero, Pickup 4WD & Ram-50 4WD)
Raise and support vehicle. Remove and support brake calipers.
Place hub in free-wheeling position. Remove drive hub cover using an
oil filter wrench and protective cloth. Remove snap ring, shim and
free-wheeling hub from drive axle. See Fig. 7. Remove lock washer.
Remove lock nut using Lock Nut Wrench (MB990954). Remove front hub
assembly.
Fig. 7: Exploded View of Front Brake Assembly (4WD)
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Install front hub assembly. Install and tighten lock nut
to 94-145 ft. lbs. (127-197 N.m), and then loosen and retighten to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Reverse removal
procedure for remaining components. After installation is complete,
check drive axle end play. Adjust end play if not .002" (.05 mm) or
less. Rotate drive axle forward and rearward until maximum end play is
obtained.
2) If adjusting axle shaft end play, use proper shim to
obtain desired end play. Shim is located behind snap ring on end of
drive axle. Install shim, and recheck axle end play.
Removal (Pickup 2WD & Ram-50 2WD)
Raise and support vehicle. Remove front caliper. Remove hub
(dust) cap, cotter pin and nut. Remove washer and outer wheel bearing.\
Remove front hub assembly. Remove bolts attaching rotor to front hub,
and separate assemblies.
Page 221 of 1333
Maximum Refinish Diameter ..................... 10.1 (257)
Wheel Cylinder Diameter
Montero ................................... .875 (22.22)
Pickup & Ram-50
2WD ..................................... .937 (23.80)
4WD ..................................... .875 (22.22)
Discard Diameter ........................... 10.12 (257.0)
(1) - Information is not available.
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE \
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Application Ft. Lbs. (N.m)
Caliper Guide or Lock Pin Bolt
Guide Pin Bolt ........................... 29-36 (40-49)
Lock Pin Bolt ............................ 23-30 (31-41)
Caliper Mounting Bolts ..................... 58-72 (79-98)
Front Wheel Bearing Nut .............................. ( 1)
Rotor-To-Hub Bolts Or Nuts
Pickup (2WD) ............................ 34-38 (46-52)
All Others ............................... 36-43 (49-58)
INCH Lbs. (N.m)
Master Cylinder-To-Power Brake Unit Nut .... 72-108 (8-12)
( 1) - See FRONT BRAKE ROTOR under REMOVAL & INSTALLATION.
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Page 263 of 1333
must be installed in original location.
2) Using bearing puller, remove differential case side
bearings. Loosen ring gear retaining bolts in diagonal sequence.
Remove ring gear.
3) Remove drive pinion shaft lock pin from ring gear side.
Remove pinion shaft and pinion gears. Remove side gears and thrust
spacers.
DRIVE PINION
1) Remove pinion flange nut. Scribe alignment mark on pinion
flange and pinion. Remove flange. Using soft-faced hammer, drive out
pinion. Remove rear bearing and oil seal from carrier. Remove rear
adjusting shim from pinion.
2) Press front bearing from pinion. Remove front adjusting
shim and spacer from pinion. Inspect all components for unusual wear
or damage. Replace as necessary.
DIFFERENTIAL REASSEMBLY & ADJUSTMENTS
CASE REASSEMBLY
1) Place side gear thrust spacers behind side gears in
original position. Assemble side gears in differential case. Install
pinion gears and washers. Rotate pinion gears to mesh with side gears.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. Using
dial indicator, measure gear backlash. See Fig. 3.
3) Backlash must be within specification. See PINION & SIDE
GEAR BACKLASH SPECIFICATIONS table. Adjust backlash by using different
side gear spacers. Ensure both sides are equally shimmed.
4) Install pinion shaft lock pin. Securely stake in 2 places.
Ensure adhesive is removed from ring gear mounting bolts and gear
mounting surface. Clean internal threads with tap.
5) Install ring gear on differential case. Ensure alignment
marks on differential case and ring gear are aligned. Apply Loctite
271 to bolts and install. Tighten bolts alternately in diagonal
sequence to specification. See TORQUE SPECIFICATIONS table at the end
of this article.
PINION & SIDE GEAR BACKLASH SPECIFICATIONS
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Application In. (mm)
Standard ....................... .003 (.08)
Wear Limit ..................... .008 (.20)
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Page 265 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual 1) Install pinion bearing races in carrier. For front race
use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L a\
nd
2.6L models and Race Installer (MB990935-01) for 3.0L model](/img/19/57332/w960_57332-264.png "MITSUBISHI MONTERO 1991 Owners Manual 1) Install pinion bearing races in carrier. For front race
use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L a\
nd
2.6L models and Race Installer (MB990935-01) for 3.0L model")
1) Install pinion bearing races in carrier. For front race
use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L a\
nd
2.6L models and Race Installer (MB990935-01) for 3.0L models. For rear\
race, use Handle and Race Installer (MB990936-01). Ensure races are
fully seated.
2) Install Pinion Height Gauge (MB990901-01) and pinion
bearings. See Fig. 4. DO NOT install oil seal. Using INCH lb. torque
wrench, measure pinion rotating torque. Gradually tighten pinion
height gauge to increase rotating torque to proper specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
3) Install Cylinder Gauge (MB990903-01) in side bearing
seats. Ensure flat areas are aligned and gauge contacts side bearing
seat firmly. See Fig. 4.
4) Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge. Use minimum amount of
adjusting shims. Install selected adjusting shims between drive pinion
gear and rear pinion bearing. Using Bearing Installer (MB990802-01),
install rear pinion bearing.
PINION ROTATING TORQUE SPECIFICATIONS
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Application INCH Lbs. (N.m)
With Oil Seal
2.4L & 2.6L Engines . 3.04-3.91 (.35-.45)
3.0L Engine ........... 5.21-6.08 (.6-.7)
Without Oil Seal
2.4L & 2.6L Engines . 1.30-2.17 (.15-.25)
3.0L Engine ........... 3.47-4.34 (.4-.5)
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Fig. 4: Setting Pinion Depth
Courtesy of Chrysler Motors.
DRIVE PINION PRELOAD
Page 266 of 1333
1) Install drive pinion in differential carrier. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion flange, washer and retaining
nut. Check pinion rotating torque without pinion oil seal.
2) Recheck rotating torque. Rotating torque must be within
specification. See PINION ROTATING TORQUE SPECIFICATIONS table. Adjust
rotating torque by replacing drive pinion front shims or spacer. Once
correct rotating torque is obtained, install oil seal. Coat seal lip
with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install new
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See PINION
ROTATING TORQUE SPECIFICATIONS table.
SIDE BEARING
1) Using Bearing Installer (MB990802-01), install bearings o\
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differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges, measure clearance between carrier and side bearing shim
at opposite sides of bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add removed shim
thickness and 1/2 of feeler gauge clearance measurement plus .002" (.
05 mm). This is thickness of shim that should be installed on each
side of case. Select proper shims. Install equal shims on each side of
case assembly.
NOTE: Ensure no clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Check ring gear
backlash.
RING GEAR BACKLASH
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash must be within .004-.006" (.10-.15 mm).
2) If not within specification, change side bearing adjusting
shims and recheck backlash. If backlash is too small, install thinner
shim behind ring gear and thicker shim opposite ring gear.
3) If backlash is excessive, install thicker shim behind ring
gear and thinner shim opposite ring gear. Check gear tooth contact
using paint impression method.
CAUTION: When changing shims, total thickness of all shims must
remain constant.
RING GEAR RUNOUT
Using dial indicator, measure runout at back side of ring
gear. Runout must be within .002" (.05 mm). If runout is excessive,
change ring gear-to-differential case mounting position. Recheck
runout. Install cover and gasket.
Page 267 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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TORQUE SPECIFICATIONS \
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Application")
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)
Bearing Cap Bolt ...................... 40-47 (54-64)
Brake Caliper Bolt .................... 58-72 (79-98)
Carrier-to-Housing Tube Bolt .......... 58-72 (79-98)
Cover Bolt ............................ 11-16 (15-22)
Drain Plug ............................ 43-51 (58-69)
Fill Plug ............................. 29-43 (39-58)
Front Crossmember Bolt ............... 72-87 (98-118)
Hub Cover ............................. 13-25 (18-34)
Knuckle-to-Ball Joint Nut
Upper ............................... 43-65 (58-88)
Lower ............................ 87-130 (118-176)
Mount Bracket-to-Frame Bolt .......... 58-80 (79-108)
Mount Bracket-to-Housing Tube Bolt ... 58-72 (79-98)
Pinion Flange Nut
2.4L & 2.6L ..................... 116-159 (157-216)
3.0L ............................ 137-181 (186-245)
Drive Shaft Flange Bolt ............... 36-43 (49-58)
Right Drive Axle-to-Inner Shaft Bolt .. 36-43 (49-58)
Ring Gear-to-Case Bolt ................ 58-65 (79-88)
Tie Rod-to-Knuckle Nut ...................... 33 (45)
Wheel Lug Nuts
Montero ............................ 72-87 (98-188)
Pick-Up .......................... 87-101 (118-137)
INCH Lbs. (N.m)
Undercover-to-Frame
Bolts (Montero) ................. 84-108 (9.5-12.2)
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Page 270 of 1333
![MITSUBISHI MONTERO 1991 Owners Manual PROBLEM
Possible Cause Action
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Possible Cause Action
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PROBLEM
Possible Cause Action
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GREASE LEAKING
Ripped CV Boot ................................... Replace Boot
CLICKING NOISE WHILE CORNERING
Dry/Worn CV Joints .................... Replace Outer CV Joints
CLUNK ON ACCELERATION
Dry/Worn CV Joints .................... Replace Inner CV Joints
Worn Trans. Gears/Bearings ..................... Inspect Trans.
VIBRATION/SHUDDER ON ACCELERATION
Dry/Worn CV Joints .......................... Replace CV Joints
Alignment Out ................................. Check Alignment
Incorrect Spring Height ................... Check Spring Height
SQUEALING OR HUMMING
Dry/Worn CV Joints ..................... Lube/Replace CV Joints
Faulty Wheel Bearing .................... Replace Wheel Bearing
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TESTING & INSPECTION
AXLE SHAFT END PLAY
Using dial indicator, check axle shaft end play. End play
must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shims to obtain correct end play. See AXLE
SHAFTS under REMOVAL & INSTALLATION.
AXLE TOTAL BACKLASH
1) Raise and support rear axle. Place transmission in
Neutral. Apply parking brake. Rotate drive shaft clockwise. Place
reference marks on pinion dust cover and differential housing.
2) Rotate drive shaft counterclockwise and measure distance
between reference marks. Differential must be removed and backlash
adjusted if distance exceeds 0.2" (5.0 mm).
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel free of ground and remove wheel. Use Axle Puller
Adapter (MB990241) for Montero and Pickup models. Install adapter on
wheel studs. Release parking brake.
2) Using torque wrench, measure starting torque on Pickup
models while rotating wheel in forward direction. On Montero models,
measure rotating torque. This measurement is read once axle is
turning. Differential must be repaired if torque is less than
specification. See TESTING SPECIFICATIONS table.
Page 272 of 1333
thickness into left side axle housing. Install left axle shaft
assembly into axle housing and tighten nuts to specification. See
TORQUE SPECIFICATIONS table at the end of this article.
2) Install right axle shaft assembly into axle housing
WITHOUT a shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case and rear axle housing end with a feeler gauge.
3) Select shims equal to the sum of the thickness of the
measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle
shaft and install the selected shim(s) and "O" ring into right axle
housing end. Install right axle shaft assembly into rear axle housing.
Tighten nuts in diagonal sequence to specification. See TORQUE
SPECIFICATIONS table.
4) Using dial indicator, check end play of axle shaft. End
play must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake and bleed brake system.
DIFFERENTIAL CARRIER
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support
differential carrier with jack. Remove differential carrier retaining
nuts. Remove differential carrier.
Inspection
Inspect for leakage at vent plug, differential carrier
companion flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts. Remove drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.
OVERHAUL
AXLE SHAFTS
Disassembly
1) Mount backing plate and axle shaft assembly in soft-jawed
vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench
(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall\
lock nut on axle shaft approximately 3 turns.
2) Attach Bearing Puller (MB990787-01) to rear of backing
plate to remove bearing case from axle shaft. See Fig. 2. Using equal
pressure to avoid binding, tighten puller nuts diagonally to remove
bearing case. Using hammer and drift, remove bearing outer race from
bearing case. Remove oil seal from end of axle housing with Slide
Hammer and Adapter (MB990211).