brake MITSUBISHI MONTERO 1991 Repair Manual

required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling,
but the vehicle's shocks or struts have not failed. In this
case, replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement

1 - 20 Amp (Yellow)
Hazard Light, Dome Light, Clock
2 - 10 Amp (Red)
Taillights
3 - 10 Amp (Red)
Turn Signal Lights
4 - 10 Amp (Red)
Back-Up Lights, Gauges
5 - 15 Amp (Light Blue)
Defogger
6 - 20 Amp (Yellow)
Heater
7 - 15 Amp (Light Blue)
Stoplights
8 - 15 Amp (Light Blue)
Horn, Wiper, Washer
9 - 10 Amp (Red)
Rear Wiper, Rear Washer
10 - 15 Amp (Light Blue)
Cigarette Lighter, Radio
CAUTIONS & WARNINGS
RADIATOR FAN & CAP
DO NOT loosen or remove radiator cap when cooling system is
hot. The system is under high pressure, and hot steam or boiling
liquid could gush out if cap is loosened or removed while system is
hot.
BRAKE FLUID
Be careful when handling brake fluid as it is harmful to eyes
and may damage painted surfaces.
REPLACING BLOWN FUSE
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.

GEA R T O OTH C O NTA C T P A TTE R NS

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Gear Tooth Contact Patterns
* PLEASE READ THIS FIRST *
The following article is for GENERAL INFORMATION purposes
only. Information does not SPECIFICALLY apply to all years, makes and
models, but is to be used as a general reference guide.
INSPECTION
PRELIMINARY INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect
for wear or damage. Mount dial indicator to housing, and check
backlash at several points around ring gear. Backlash must be within
specifications at all points. If no defects are found, check gear
tooth contact pattern.
GEAR TOOTH CONTACT PATTERN
NOTE: Drive pattern should be well centered on ring gear teeth.
Coast pattern should be centered, but may be slightly toward
toe of ring gear teeth.
1) Paint ring gear teeth with marking compound. Wrap cloth or
rope around drive pinion flange to act as brake. Rotate ring gear
until clear tooth contact pattern is obtained.
2) Contact pattern will indicate whether correct pinion
bearing mounting shim has been installed and if drive gear backlash
has been set properly. Backlash between drive gear and pinion must be
maintained within specified limits, until correct tooth pattern is
obtained.

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE









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Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels

Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\

Torque Converter Clutch Solenoid/Switch ......... Engine Performance
Traction Control Switch ........................... Anti-Lock Brakes
Trailer Tow Connector .............................. Exterior Lights
Trailer Tow Relay .................................. Exterior Lights
Transmission/Transaxle .......................... Engine Performance
Transmission Control Module (TCM) ............... Engine Performance\
Starters
Transmission Range Sensor ................................. Starters
Back-Up Lights
Engine Performance
Transmission Range Switch ........................... Back-Up Lights
Engine Performance
Anti-Theft System
Turn Signal Flasher ................................ Exterior Lights
Turn Signal Lights ................................. Exterior Lights
Twilight Sentinel Switch ......................... Headlight Systems
Daytime Running Lights
Vapor Canister Leak Detection Pump .............. Engine Performance
Vehicle Control Module (VCM) .................... Engine Performance\
Vehicle Dynamic Module ....................... Electronic Suspension
Vehicle Speed Control Servo ................. Cruise Control Systems
Vehicle Speed Sensor .......................... Data Link Connectors
Analog Instrument Panels
Cruise Control Systems
Electronic Suspension
Voltage Regulator .......................... Generators & Regulators
Water-In-Fuel Sensor ............................ Engine Performance
Analog Instrument Panels
Wheel Speed Sensors ............................... Anti-Lock Brakes
Window Timer Module .......................... Power Convertible Top
Windshield Intermittent Wiper Relay ........... Wiper/Washer Systems
Windshield Washer Motor ....................... Wiper/Washer Systems
Wiper Motor ................................... Wiper/Washer Systems









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LO CKIN G H UBS

1991 M it s u bis h i M onte ro
1991 DRIVE AXLES
Locking Hubs
Mitsubishi: Montero, Pickup
DESCRIPTION
Automatic hubs are engaged by rotational force of axle shaft
when 4WD is selected at transfer case. Automatic hubs disengage when
2WD is selected or vehicle is driven in Reverse. Cams, brakes and
springs are used to lock or unlock automatic hubs.
Engagement is accomplished through gears and spring actions
within hub. When hub is locked, hub brake engages inner hub, which is
connected to axle shaft by inner splines of hub. Hub brake is
connected to hub body by outer splines.
REMOVAL
1) Hub must be unlocked. To unlock hub, place transfer case
lever in 2H position and move vehicle in Reverse approximately 4-6
feet.
2) Remove cover from locking hub. If hub cover cannot be
loosened by hand, wrap shop towel around cover and use an oil filter
wrench to loosen cover.
3) Raise and support vehicle. Remove wheel assembly. Using
snap ring pliers, remove snap ring and shim from end of axle. Remove
locking hub retaining bolts. Remove locking hub.
INSTALLATION
1) To install, reverse removal procedure. Apply sealant to
contact areas between locking hub assembly and hub/rotor assembly.
Ensure sealant is NOT applied on outer areas of hub/rotor assembly
toward brake contact areas.
2) Align locking hub assembly key area with steering knuckle
key way area. Loosely install locking hub assembly on hub/rotor
assembly. Ensure locking hub assembly fully contacts hub/rotor
assembly.
3) Install locking hub retaining bolts. Tighten bolts to 36-
43 ft. lbs. (49-58 N.m). Using spring scale attached to wheel stud,
measure turning resistance required to rotate hub/rotor assembly.
4) Turning resistance should NOT exceed 3.1 lbs. (1.4 kg). I\
f
turning resistance exceeds specification, check for incorrect
installation of locking hub assembly or components.
5) Install shim and snap ring on drive axle. Rotate drive
axle until maximum end play is obtained. Using a dial indicator, check
drive axle end play.
6) Drive axle end play should be .008-.020" (.20-.51 mm). If\
axle end play is NOT within specification, adjust end play by changing
axle shaft shim. Install hub cover. Tighten hub cover 13-25 ft. lbs.
(18-34 N.m).
OVERHAUL
DISASSEMBLY

1) Remove locking hub. See REMOVAL & INSTALLATION. Push brake
"B" in hub housing and remove housing "C" ring. See Fig. 1. Using
Adapter (MB990811-01), lightly press drive gear assembly and remove
"C" ring from retainer "B". Slowly release drive gear assembly.
2) Remove drive gear assembly, slide gear assembly and return
spring. Remove slide gear "C" ring. Remove shift spring.
Fig. 1: Exploded View of Locking Hub
Courtesy of Chrysler Motors.
INSPECTION

1) Check drive gear and slide gear splines for damage. Check
cam portion of retainer "A" for wear or damage. Check cam for wear and
damage. Check slide gear and housing tooth surfaces for damage. Check
retainer "B" and housing contact surfaces for wear and damage.
2) Check brake assembly thickness. See Fig. 2. Assemble brake
"A" and brake "B". Using slide calipers, measure thickness of
assembled brake at both brake "A" lugs.
3) Standard thickness is .413" (10.49 mm). Minimum thickness\
is .378" (9.60 mm). If measured thickness is less than minimum
thickness, replace brake "A" and brake "B".
4) Check length of return spring. Measure length "A" of
spring. Ensure length "A" is 1.38" (35.1 mm). See Fig. 3. If length
"A" is NOT as specified, replace return spring.
5) Check length of shift spring. Measure length "B" of
spring. Ensure length "B" is 1.18" (30.0 mm). See Fig. 3. If length
"B" is NOT as specified, replace shift spring.
Reassembly Pack grooves of retainer "B" with multipurpose
grease and apply grease to attaching surfaces of all components. To
complete assembly, reverse disassembly procedure.
Fig. 2: Measuring Brake Assembly Thickness
Courtesy of Chrysler Motors.