MITSUBISHI MONTERO 1998 Service Manual
Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 1151 of 1501
deploys.
* After air bag deploys, air bag surface may contain deposits
of sodium hydroxide, which irritate skin. Always wear safety
glasses, rubber gloves and long-sleeved shirt during clean
up. Wash hands using mild soap and water. Follow correct
clean-up and disposal procedures.
* Because of critical system operating requirements, DO NOT
service any SRS components. Repairs are only made by
replacing defective part(s).
* DO NOT allow any electrical source near inflator on the back
of air bag module.
* When carrying live air bag module, trim cover should be
pointed away from body to minimize injury in case of
accidental air bag deployment.
* If SRS is not fully functional for any reason, DO NOT drive
vehicle until system is repaired and is fully functional. DO
NOT remove bulbs, modules, sensors or other components, or in
any way disable system from operating normally. If SRS is not
functional, park vehicle until repairs are made.
REMOVAL & INSTALLATION
STEERING WHEEL
WARNING: Wait at least 60 seconds after disconnecting negative
battery cable before servicing SRS. System reserve capacitor
maintains SRS voltage for about 60 seconds after battery is
disconnected. Servicing SRS before 60-second period may
cause accidental air bag deployment and possible personal
injury.
Removal
Disable air bag. See DISABLING & ACTIVATING AIR BAG SYSTEM .
Ensure steering wheel is straight ahead. Remove air bag. Place
reference mark on steering wheel and steering column shaft for
installation reference. Remove steering wheel nut and washer. Using
steering wheel puller, remove steering wheel.
CAUTION: DO NOT hammer on steering wheel during removal or
installation, as it may damage steering column.
Installation
To install, reverse removal procedure. Ensure reference marks
are aligned. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS . Activate air bag. See DISABLING & ACTIVATING
AIR BAG SYSTEM.
COMBINATION SWITCH
CAUTION: When installing steering wheel, if rotating part of
clockspring is not properly centered with steering column
and front wheels, clockspring failure will result.
Removal & Installation
Remove lower instrument cover and lower heater duct. Remove
air bag and steering wheel. See STEERING WHEEL under
REMOVAL & INSTALLATION . Remove upper and lower steering column covers.
Disconnect clockspring electrical connector. Remove screws attaching
colckspring and remove clockspring. Disconnect combination switch
electrical connectors. Remove screws and combination switch. To
install, reverse removal procedure.
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IGNITION SWITCH
Removal & Installation
1) Remove upper and lower steering column covers. Disconnect
harness connector from ignition switch. Using hacksaw, cut slots in
bolt heads of lock assembly. Using screwdriver, remove bolts and lock
assembly.
2) To install, reverse removal procedure. Tighten new bolts
until heads of bolts sheer off.
STEERING COLUMN
WARNING: Failure to follow air bag service precautions may result in
air bag deployment and personal injury. See AIR BAG SERVICE
PRECAUTIONS. Follow all service precautions before
attempting repairs. After component replacement, perform a
system operational check to ensure proper system operation.
CAUTION: Applying excessive pressure or causing impact to steering
shaft during service may cause column to collapse. Before
removing steering column, ensure wheels are in
straight-ahead position. Note steering wheel location for
installation reference.
Removal
1) Remove steering wheel. Remove combination switch and
ignition switch (if necessary). See STEERING WHEEL under
REMOVAL & INSTALLATION .
2) Remove lower instrument panel cover and air duct.
Disconnect all electrical connections. Disconnect brake pedal return
spring (if equipped). Disconnect gearshift control cable.
3) Remove bolts for dust cover at firewall. Remove bolt from
clamp at steering gear. Remove steering column bolts and remove
steering column.
Installation
To install, reverse removal procedure. Apply sealant (3M ATD
8663) to dust cover bolts before installing. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
OVERHAUL
STEERING COLUMN
WARNING: Failure to follow air bag service precautions may result in
air bag deployment and personal injury. See AIR BAG SERVICE
PRECAUTIONS. Follow all service precautions before
attempting repairs. After component replacement, perform a
system operational check to ensure proper system operation.
NOTE: Vehicle steering column is not repairable. See below for
joint assembly and steering lock removal and installation.
Disassembly
Remove steering column from vehicle. See STEERING COLUMN
under REMOVAL & INSTALLATION . Remove clamp bolt from joint assembly.
See Fig. 1 . Remove assembly. Remove lower boot, upper boot and dust
cover from joint assembly. To remove steering lock, use a hacksaw to
cut bolts at steering lock bracket side. Remove steering lock and
bracket.
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Fig. 1: Exploded View Of Steering Column (Montero Shown, Montero
Sport Similar)
Courtesy of Mitsubishi Motor Sales of America.
Reassembly
1) To reassemble, reverse disassembly procedure. Install
upper boot on joint assembly. Install lower boot and dust cover on
joint assembly. Leave boots on shafts without assembling them to
universal joint.
2) Apply multipurpose grease to universal joints of joint
assembly. When installing upper boot, lower boot and dust cover,
ensure arrows on boots align with slit area on yoke. Align steering
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lock with column boss. Ensure steering lock is operational. Tighten
bolt until bolt head breaks off.
3) Assemble upper steering column with lower joint assembly.
Ensure mating mark on lower steering shaft aligns with yoke groove in
upper steering shaft. See Fig. 2. Apply thread sealant to bolts and
nuts of lower steering column.
Fig. 2: Aligning Mating Mark
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS\
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Application Ft. Lbs. (N.m)\
Column Bracket Bolts
Montero ................................................. 16 (22)\
Montero Sport ............................................... ( 1)
Lower Steering Shaft Clamp Bolt
Montero ........................................... 22-25 (30-34)\
Montero Sport ........................................... 14 (19)\
Steering Wheel Nut ......................................... 29 (40)\
Upper Steering Shaft Clamp Bolt ............................ 13 (18)\
Dust Cover Bolt
Montero ................................................... 3 (4)\
Montero Sport ............................................... ( 1)
Air Bag Bolts ................................................ 7 (9)\
Steering Column Tube Clamp ................................... 4 (5)\
( 1) - Tighten bolts to 106 INCH lbs. (12 N.m).
( 2) - Tighten bolts to 43 INCH lbs. (4.9 N.m).
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STEERING SYSTEM - POWER RECIRCULATING BALL
1998 Mitsubishi Montero
1997-98 STEERING
Mitsubishi - Power Recirculating Ball
Montero, Montero Sport
DESCRIPTION & OPERATION
STEERING GEAR
The power steering gear displaces fluid to provide hydraulic
pressure assist while turning. A one-piece rack piston nut is geared
to cross shaft. Backlash is adjusted with an adjusting screw.
STEERING LINKAGE
Linkage consists of an idler arm, relay rod, steering
knuckles and adjustable tie rods. Components are connected by ball
joints. Linkage assembly is connected to steering gear by pitman arm.
LUBRICATION
FLUID TYPE
Recommended fluid type is Dexron-II ATF.
FLUID LEVEL CHECK
Place vehicle in level position. Start engine and let idle.
Turn steering wheel left and right. Replace fluid if it has bubbles or
has become White. Fluid level should be between MIN and MAX marks on
dipstick. Fill to proper level.
FLUID REPLACEMENT
CAUTION: DO NOT crank engine for more than 15-20 seconds at a time.
1) Remove reservoir cap. Disconnect return hose at reservoir.
Drain fluid. Disconnect coil high tension wire. Raise and support
vehicle.
2) Turn steering wheel lock-to-lock several times while
cranking engine to drain fluid from steering gear. Reconnect hose.
Fill power steering system with fluid. Bleed system. See
HYDRAULIC SYSTEM BLEEDING .
HYDRAULIC SYSTEM BLEEDING
CAUTION: DO NOT crank engine for more than 15-20 seconds at a time.
Add fluid as needed during procedure to prevent reservoir
level from dropping.
1) Ensure reservoir is filled before bleeding. Add fluid (if
necessary) during bleeding. Raise and support front of vehicle.
Disconnect coil high tension wire.
2) While cranking engine, turn steering wheel lock-to-lock 5
or 6 times. Lower vehicle. Connect coil wire. Start engine and let
idle. Turn steering wheel lock-to-lock until no more bubbles appear in
oil reservoir.
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3) Turn steering wheel lock-to-lock. Fluid level should not
change more than .2" (5 mm). If pump is noisy, fluid rises after
engine is turned off, or fluid level changes more than specified,
repeat bleeding procedure.
ADJUSTMENTS
BELT TENSION ADJUSTMENT SPECIFICATIONS
BELT ADJUSTMENT \
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Application ( 1) Deflection: In. (mm)
Montero
New Belt ......................................... .42-.54 (11-14)\
Used Belt ........................................ .58-.66 (15-17)\
Montero Sport
2.4L
New Belt ......................................... .16-.24 (4-6)\
Used Belt ........................................ .24-.28 (6-7)\
3.0L
New Belt ....................................... .44-.52 (11-13)\
Used Belt ...................................... .56-.64 (14-16)\
( 1) - With 22 lbs. (10 kg) pressure applied midway on longest belt
run.
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STEERING WHEEL PLAY
Raise and support vehicle. Start engine and let idle. With
steering wheel in center position, ensure free play is 1.1" (27 mm) or\
less. If measured value exceeds specification, check steering gear
backlash and linkage ball joint end play. See STEERING GEAR BACKLASH
and LINKAGE BALL JOINT END PLAY.
STEERING GEAR BACKLASH
1) Set steering wheel in straight-ahead position. Raise and
support vehicle. Disconnect relay rod from pitman arm. Using a dial
indicator, measure steering gear backlash at top end of pitman arm.
2) Steering gear backlash should not exceed .02" (.5 mm). If\
measured value exceeds limit, turn steering gearbox adjusting bolt
until steering wheel free play is within specification. See Fig. 1.
Fig. 1: Measuring Steering Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.
TESTING
Page 1157 of 1501
HYDRAULIC SYSTEM PRESSURE TEST
1) Disconnect pressure hose from power steering pump. Attach
Pressure Gauge (MB990662-01) and Adapters (MB990993-01 and MB990994-
01). See Fig. 2. Tighten fittings to 22-29 ft. lbs. (30-39 N.m).
2) Bleed system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION . Turn wheel several times to bleed air from gauge. Start
engine and let idle. Place thermometer in reservoir. Check fluid
level. Add fluid as necessary.
3) When fluid temperature reaches 122-140
F (50-60C), check
pressure. See POWER STEERING PUMP PRESSURE SPECIFICATIONS table.
Reinstall pressure hose. Do not twist hose or let hose interfere with
adjacent parts. Replace power steering pump if pressure is not within
specification. Bleed system.
CAUTION: DO NOT keep shutoff valve closed more than 3 seconds at a
time. DO NOT keep steering wheel turned to full lock
position for more than 10 seconds at a time.
POWER STEERING PUMP PRESSURE SPECIFICATIONS
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Application psi (kg/cm)
Valve Closed Or Wheel At Full Lock ............... 1204-1305 (83-90)\
Valve Open (Standard) ............................... 114-142 (8-10\
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Fig. 2: Connecting Pressure Gauge & Shutoff Valve
Courtesy of Mitsubishi Motor Sales of America.
P/S PRESSURE SWITCH
Page 1158 of 1501
1) Disconnect pressure hose from power steering pump. Attach
Pressure Gauge (MB990662-01) and Adapters (MB990993-01 and MB990994-
01). See Fig. 2. Tighten fittings to 22-29 ft. lbs. (30-39 N.m).
2) Bleed system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION . Turn wheel several times to bleed air from gauge. Start
engine and let idle. Place thermometer in reservoir. Check fluid
level. Add fluid as necessary.
3) When fluid temperature reaches 122-140
F (50-60C),
disconnect connector from P/S pressure switch. Connect ohmmeter across
switch terminals. Slowly close shut-off valve. Check pressure when
ohmmeter indicates switch has closed (continuity). Pressure should be
218-290 (15-20 N.m). Slowly open shut-off valve. Check pressure when
ohmmeter indicates switch has opened (no continuity). Pressure should
be 102-174 (7-12 N.m). Reinstall pressure hose. Do not twist hose or
let hose interfere with adjacent parts. Replace P/S pressure switch if
pressure is not within specification. Bleed system.
CAUTION: DO NOT keep shutoff valve closed more than 3 seconds at a
time. DO NOT keep steering wheel turned to full lock
position for more than 10 seconds at a time.
STEERING WHEEL TURNING FORCE
Stationary Test
1) Position vehicle on level surface. Place steering wheel in
straight-ahead position. Start engine and let idle. Using a spring
scale, measure steering wheel turning force clockwise and
counterclockwise.
2) On Montero, turning force should be 8.2 lbs. (3.7 kg) or
less. On Montero Sport, turning force should be 8.8 lbs. (3.9 kg) or
less. If turning force exceeds specification, check for loose or
damaged belt, insufficient fluid, air in power steering fluid, and
collapsed or twisted hoses. Repair or replace as necessary.
REMOVAL & INSTALLATION
IDLER ARM
Removal
Loosen relay rod-to-idler arm lock nut. Using Steering
Linkage Puller (MB991113 or MB990635), separate idler arm from relay
rod and remove relay rod-to-idler arm lock nut. Remove idler arm bolts
and nuts. Remove idler arm. On Montero, loosen, but DO NOT remove
idler arm-to-bracket nut. Press arm from bracket and remove nut and
arm.
Inspection
Check idler arm bushings for damage or wear. Check idler arm
ball stud for looseness.
Installation
1) Apply multipurpose grease to inside surface of bushing and
idler arm support shaft. Insert bushing in idler arm. Insert idler arm
support in idler arm.
2) Install washer (knurled side toward bushing) and NEW lock\
nut. Tighten lock nut to specification. See TORQUE SPECIFICATIONS.
Place idler arm assembly in vise. Using a spring gauge, measure
turning resistance.
3) On all models, turning resistance should be 3-18 INCH lbs.
(.3-2.0 N.m). On Montero, if turning resistance is not within
specification, loosen or tighten lock nut to obtain proper resistance.
4) Install idler arm bolts and nuts. Install relay rod-to-
Page 1159 of 1501
idler arm. See TORQUE SPECIFICATIONS .
POWER STEERING GEAR
Removal & Installation
1) Drain power steering fluid. See FLUID REPLACEMENT under
LUBRICATION . Remove steering shaft-to-steering gear clamp bolt.
Disconnect pressure and return hoses from steering gear.
2) Remove cotter pin and castle nut from pitman arm. Using
Puller (C-3894-A), separate pitman arm from relay rod.
3) Remove steering gear mounting nuts. Disconnect steering
shaft from steering gear. Remove steering gear. To install, reverse
removal procedure.
POWER STEERING PUMP & RESERVOIR
Removal
Drain power steering fluid. See FLUID REPLACEMENT under
LUBRICATION . Disconnect hoses from reservoir. Remove reservoir.
Disconnect hoses from pump. Loosen pump retaining bolts. Remove belt.
Remove pump and mounting bracket(s).
Installation
To install, reverse removal procedure. Check power steering
pump bracket for slack. Tighten bracket (if necessary). Fill and bleed\
reservoir. See FLUID REPLACEMENT and HYDRAULIC SYSTEM BLEEDING under
LUBRICATION . Start engine and turn steering wheel lock-to-lock to
check for fluid leaks.
RELAY ROD
Removal
Remove inner tie rod end cotter pins and lock nuts. Separate
tie rod ends from relay rod. Remove cotter pins and castle nuts from
idler arm and pitman arm. Using a puller, separate relay rod from
idler arm and pitman arm.
Installation
To install relay rod, reverse removal procedure. Ensure dust
covers are well greased and lower edge of covers are coated with
packing sealer. Tighten relay rod-to-idler arm and relay rod-to-pitman
arm castle nuts to specification. See TORQUE SPECIFICATIONS.
TIE ROD ASSEMBLY
Removal
1) Remove skid plate (if necessary). Remove cotter pins and
loosen lock nuts from tie rod ball studs at steering knuckle and relay
rod end.
2) Using Steering Linkage Puller (MB991113 or MB990635),
separate tie rod ends from knuckle and relay rod end and remove lock
nuts. Loosen tie rod adjusting sleeve lock nuts, and unscrew tie rod
ends.
Inspection
Check tie rod ends for damage and ball studs for looseness.
On Montero, measure ball stud starting torque. Torque should be 9-27
INCH lbs. (1.0-3.0 N.m). If ball stud starting torque exceeds
specification, replace tie rod.
Installation
1) Install "O" ring on ball socket. Grease inside of tie rod
Page 1160 of 1501
end dust cover. Coat lower edge of cup with packing sealer. Install
tie rod ends into adjusting sleeves.
2) Measure center-to-center distance between tie rod studs
for both tie rod assemblies. Adjust center-to-center distance to
specification. See TIE ROD INSTALLATION LENGTH table.
3) An equal number of threads should be visible on each side
of adjusting sleeve. Install tie rod ends in steering knuckle and
relay rod. Install tie rod end castle nuts and NEW cotter pins.
Tighten castle nuts to specification. See TORQUE SPECIFICATIONS.
Adjust toe-in. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article
in WHEEL ALIGNMENT section.
TIE ROD INSTALLATION LENGTH
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Application In. (mm)\
Montero .............................................. 12.05 (306.0)\
Montero Sport ........................................... 12.0 (305)\
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OVERHAUL
POWER STEERING GEAR
Disassembly
1) Scribe mating marks on pitman arm and cross shaft. Remove
pitman arm nut. Using a puller, remove pitman arm. Drain power
steering fluid. Remove side cover bolts. See Fig. 3. Loosen adjusting
bolt lock nut, and screw in adjusting bolt so side cover raises
slightly.
2) With mainshaft and cross shaft placed in straight-ahead
position, tap bottom of cross shaft with plastic hammer. Remove cross
shaft and side cover as an assembly. Remove side cover from cross
shaft by turning adjusting bolt.
3) Remove valve housing and rack piston as an assembly by
turning rack piston counterclockwise. See Fig. 3. Carefully remove
rack piston from mainshaft without losing balls inside rack piston.
4) Remove cross shaft oil seal from gearbox housing. Put rack
piston in soft jawed vise. Using Spanner Wrench (MB991367) and Pin Set\
(MB991394), remove lock nut. Remove mainshaft while applying pressure
to bearing race to prevent balls from falling out. Drive out bearing
and oil seal.
NOTE: DO NOT remove cross shaft "U" packing at rear of needle
bearing unless fluid leakage is found coming from adjusting
bolt threads. If leakage exists, replace "U" packing.