clutch MITSUBISHI MONTERO 1991 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 269 of 1333
![MITSUBISHI MONTERO 1991 Workshop Manual \
\
\
\
\
\
\
KNOCKING OR CLUNKING
Differential Side Gear Clearance .](/img/19/57332/w960_57332-268.png "MITSUBISHI MONTERO 1991 Workshop Manual \
\
\
\
\
\
\
KNOCKING OR CLUNKING
Differential Side Gear Clearance .")
\
\
\
\
\
\
\
KNOCKING OR CLUNKING
Differential Side Gear Clearance .............. Check Clearance
Worn Pinion Shaft ........................ Replace Pinion Shaft
Axle Shaft End Play ............................ Check End Play
Missing Gear Teeth ................... Check Diff./Replace Gear
Wrong Axle Backlash ............................ Check Backlash
Misaligned Driveline ........................ Realign Driveline
CLUNKING DURING ENGAGEMENT
Side Gear Clearance ................. Check Side Gear Clearance
Ring and Pinion Backlash ....................... Check Backlash
Worn/Loose Pinion Shaft ................. Replace Shaft/Bearing
Bad "U" Joint ............................... Replace "U" Joint
Sticking Slip Yoke ............................. Lube Slip Yoke
Broken Rear Axle Mount .......................... Replace Mount
Loose Drive Shaft Flange ......................... Check Flange
CLICK/CHATTER ON TURNS
Differential Side Gear Clearance .............. Check Clearance
Worn Clutch Plates (1) .................. Replace Clutch Plates
Wrong Diff. Lubricant (1) .................... Change Lubricant
RHYTHMIC KNOCK OR CLICK
Flat Spot on Rear Wheel Bearing ......... Replace Wheel Bearing
HUM/LOW VIBRATION AT ALL SPEEDS
Faulty Wheel Bearings ........................ Replace Bearings
Faulty "U" Joint ............................ Replace "U" Joint
Faulty Drive Shaft ........................ Balance Drive Shaft
Faulty Companion Flange ........................ Replace Flange
Faulty Slip Yoke Flange ........................ Replace Flange
(1) - Limited slip differential only.
\
\
\
\
\
\
\
DRIVE AXLE (FWD)
DRIVE AXLE (FWD) TROUBLE SHOOTING \
\
\
\
\
\
\
Page 275 of 1333
Fig. 4: Exploded View of Typical Limited Slip Differential
Courtesy of Chrysler Motors.
Drive Pinion
1) Remove pinion flange retaining nut. Scribe alignment marks
on drive pinion and pinion flange for reassembly. Using soft-faced
hammer, drive out pinion. Remove front adjusting shim and spacer from
pinion.
2) Using bearing puller, remove rear bearing from pinion.
Remove rear adjusting shim from pinion. Remove oil seal and bearing
races from differential carrier.
Inspection
1) Inspect all gears for cracked or flaking teeth. Inspect
pinion shaft for wear. Inspect pinion flange and drive pinion for
damaged splines.
2) Inspect bearings and races for roughness or flaking.
Replace worn components. On limited slip axles, inspect clutch
components and contact areas for wear or overheating. Inspect friction
plates, friction discs, spring plates and pressure rings for signs of
seizure, excessive heat, severe friction or nicks.
NOTE: Outer areas of friction surfaces will wear heavier due to
clutch plate and preload spring.
3) Using dial indicator, check friction plate and friction
disc for warpage. Replace components if beyond specification. See
FRICTION PLATE & DISC SPECIFICATIONS table.
4) Measure friction plates and disc thickness at projection
areas not within wear area. Measure plate and disc thickness in
friction surface. Difference between thickness of projections and
friction surface indicates amount of wear. Replace components if not
Page 277 of 1333
gear. Securely stake pin in 2 places. Ensure adhesive is removed from
ring gear mounting bolts and gear mounting surface. Clean internal
threads with tap.
5) Ensure alignment marks on differential case and ring gear
are aligned. Apply Loctite 271 to bolts and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS table at the end of this
article.
CASE ASSEMBLY (LIMITED SLIP)
1) Assemble 2 friction discs and 2 friction plates; assemble
plate, disc, plate and disc. Measure assembly thickness. Assemble
discs and plates to give standard difference of .002" (.05 mm) between\
the 2 sides.
2) Assemble spring plates and spring discs with one on each
side. Measure assembly thickness. Assemble disc and plates to obtain
minimum difference in thickness between each assembly.
3) Assemble clutch assemblies, pressure rings, pinion gears,
side gears and pinion shaft. Measure overall width of assembly plus
spring plates and spring discs. This measurement is "C". See Fig. 6.
Fig. 6: Measuring Clutch Assembly Width
Courtesy of Chrysler Motors.
4) Determine depth "D" of differential case, using formula
"D"="E"+"F"-"G" or "D"="E"+"H"-"F"-"G" . See Fig. 7. Subtract
measurement "C" from measurement "D" to determine spring plate-to-case
Page 278 of 1333
clearance. Adjust spring disc thickness to obtain proper spring plate-
to-case clearance. Correct clearance is .0024-.0079" (.060-.200 mm).
Fig. 7: Measuring Limited Slip Case Depth (Montero 3.0L & Pickup)
Courtesy of Chrysler Motors.
CAUTION: DO NOT interchange clutch components for right and left
sides. Mark clutch components for location.
5) Remove spring plates, spring discs, friction plates and
friction disc from pressure rings. Mark components for location.
Install thrust washers on each end of pressure rings. See Fig. 8.
6) Measure distance from end of thrust washer to rear face of
pressure ring. Select proper thickness thrust washers to obtain a .
002" (.05 mm) or less difference between measurements.
7) Once correct thrust washers are determined, install thrust
washers on pressure rings. Squeeze pressure rings together and measure
width from end of thrust washer to remaining thrust washer. This is
dimension "H". See Fig. 8.
8) Determine distance between thrust washer surfaces when
differential case is assembled. This is dimension "I"
("I"="J"+"K"+"L"). See Fig. 8. Dimension "J" is the same as dimension
"D" in step 4).
Page 280 of 1333
Thrust washer must be changed to obtain correct specification. Correct
clearance is .002-.008" (.05-.20 mm).
10) Select thrust washers to obtain correct clearance from
pressure ring face and end of thrust washer surface. Thrust washers
are available in 3 sizes.
11) Apply gear oil and friction modifier to all components.
Install components in differential case. Ensure assembly order and
direction of clutch components are correct. See Fig. 9.
Fig. 9: Limited Slip Differential Assembly
Courtesy of Chrysler Motors.
12) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See TORQUE
SPECIFICATIONS table at end of article. Ensure cases contact each
other completely when fully assembled. Check for incorrect clutch
assembly if gap exists.
13) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. Slightly rotate\
unit before measuring starting torque. See Fig. 10.
Page 281 of 1333
Fig. 10: Checking Differential Starting Torque
Courtesy of Chrysler Motors.
14) Starting torque must be within specification. See
STARTING TORQUE SPECIFICATIONS table. Ensure adhesive is removed from
ring gear mounting bolts and gear mounting surface. Clean internal
threads with tap.
15) Ensure alignment marks on differential case and ring gear
are aligned. Apply Loctite 271 to bolts and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS table.
STARTING TORQUE SPECIFICATIONS
\
\
\
\
\
Application Ft. Lbs. (N.m)
Used Clutch Plates .................. 25-72 (34-98)
New Clutch Plates ................... 47-72 (64-98)
\
\
\
\
\
DRIVE PINION HEIGHT
1) Install pinion bearing races in carrier. Ensure races are
fully seated. Install pinion height gauge and pinion bearings. Use
Pinion Height Gauge (MB990901) for all others. See Fig. 10. DO NOT
install oil seal.
2) Using torque wrench, measure pinion rotating torque.
Gradually tighten pinion height gauge to increase rotating torque to
3.5-4.3 INCH lbs. (.40-.48 N.m).
3) Install cylinder gauge in side bearing seats. Ensure flat
areas are aligned and gauge contacts side bearing seat firmly. See
Fig. 11 . Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected
Page 289 of 1333
\003
* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS
Page 301 of 1333
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A .. Require repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Frayed .................. A ............ Require replacement.
Kinked .................. A .. Require repair or replacement.
Melted .................. A ........... (1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B ........... ( 2) Require repair or
replacement.
Routed incorrectly ...... 2 ................. Suggest repair.
Seized .................. A .. Require repair or replacement.
Self-adjuster
inoperative ............ A .. Require repair or replacement
of self-adjuster.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Cable replacement is required if it cannot be adjusted
within specifications.
\
\
\
\
\
\
\
CARRIER BEARINGS
See INTERMEDIATE SHAFT SUPPORT BEARINGS .
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH CABLE AND CABLE HOUSING INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Broken .................. A ............ Require replacement.
Cable bent .............. A ............ Require replacement.
Cable binding ........... A .. Require repair or replacement.
Cable mounting loose .... B .. Require repair or replacement.
Cable out of adjustment . B .. Require repair or replacement.
Frayed .................. B ............ Require replacement.
Housing heat-damaged .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
\
\
\
\
\
\
\
Page 302 of 1333
![MITSUBISHI MONTERO 1991 Workshop Manual CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION \
\
\
\
\](/img/19/57332/w960_57332-301.png "MITSUBISHI MONTERO 1991 Workshop Manual CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION \
\
\
\
\")
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.
\
\
\
\
\
\
\
CLUTCH FORKS
CLUTCH FORK INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
\
\
\
\
\
\
\
Page 303 of 1333
![MITSUBISHI MONTERO 1991 Workshop Manual CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION \
\
\](/img/19/57332/w960_57332-302.png "MITSUBISHI MONTERO 1991 Workshop Manual CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION \
\
\")
CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Cover gasket distorted .. A .... Require replacement of cover
gasket.
Cover gasket gummy ...... A .... Require replacement of cover
gasket.
Cylinder leaking fluid
from rear of bore ...... A .. Require repair or replacement.
Cylinder leaking fluid
internally ............. A ............ Require replacement.
Dust boot missing ....... C ..... Require replacement of dust
boot.
Dust boot punctured ..... A ..... Require replacement of dust
boot.
Dust boot torn .......... A ..... Require replacement of dust
boot.
Fluid level incorrect ... B . Require fluid level adjustment.
Housing damaged, affecting
performance ............ A .. Require repair or replacement.
Master cylinder has
residue in reservoir
(make parallel w/brakes
when they are done) .... 2 .......... ( 1) Further inspection
required.
Threads damaged ......... A ...... Require repair replacement
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - DO NOT replace master cylinder unless it exhibits
conditions listed for replacement. You may suggest fluid
change according to OEM service intervals.
\
\
\
\
\
\
\
CLUTCH PEDALS
CLUTCH PEDAL INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .......... Require replacement of
pedal pad.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.
\
\
\
\
\
\
\
CLUTCH PIVOTS
CLUTCH PIVOT INSPECTION \
\
\
\
\
\
\