MITSUBISHI MONTERO 1998 Service Manual
Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 1361 of 1501
position. Loosen adjusting nut on control cable. See Fig. 3. Gently
pull control cable from dust cover. Make sure shift lever is still in
Neutral. Tighten adjusting nut. Check transmission operation through
all ranges. Readjust control cable if necessary.
Fig. 3: Adjusting Shift Linkage (Montero)
Courtesy of Mitsubishi Motor Sales of America.
SHIFT LEVER SLEEVE
Eclipse & Galant
To adjust shift lever sleeve, remove shift handle on top of
shift lever. With lever in Neutral, turn sleeve so distance between
sleeve and lever end is within specification. See
SHIFT LEVER SLEEVE CLEARANCE SPECIFICATION table. See Fig. 4. Ensure
beveled side of sleeve faces toward push button (if equipped).
SHIFT LEVER SLEEVE CLEARANCE SPECIFICATION
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Application Clearance In. (mm)\
Eclipse & Galant ............................... .62-.64 (15.7-16.3)\
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Fig. 4: Adjusting Shift Lever Sleeve (Eclipse & Galant)
Courtesy of Mitsubishi Motor Sales of America.
NEUTRAL SAFETY SWITCH
All Models
Neutral safety switch is adjusted along with shift linkage.
See SHIFT LINKAGE .
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Drain Plug
Transaxle/Transmission
Except Montero ................................... 22-25 (30-35)\
Montero .......................................... 13-17 (18-24)\
Transfer Case ............................................ 24 (32)\
Rear Cover ................................................. 17 (23)\
INCH Lbs. (N.m)
Kickdown Servo Lock Nut ................................... 121 (29)\
Oil Filter/Screen Bolt
Except Montero ................................... 48-60 (5.4-6.8)\
Montero ................................................. 61 (6.9)\
Oil Pan Bolt
Except Montero ................................. 84-108 (9.5-12.2)\
Montero ................................................. 69 (7.8)\
Park/Neutral Switch Mounting Bolt (Except Montero) ......... 97 (11\
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Park/Neutral Switch Mounting Bolt (Montero) ............... 115 (13\
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Transmission Control Cable Adjusting Nut ................... 115 (13)\
Valve Body Cover ........................................... 97 (11)\
Page 1363 of 1501
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Page 1364 of 1501
TRANSMISSION SERVICING - M/T
1998 Mitsubishi Montero
1997-98 TRANSMISSION SERVICING
Mitsubishi Manual Transmission
Eclipse, Galant, Mirage, Montero, 3000GT
IDENTIFICATION
MANUAL TRANSMISSION APPLICATIONS \
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Model Transmission/Transaxle (Model)\
Eclipse
AWD .................................... 5-Speed Transaxle (W5M33)\
FWD
2.0L Non-Turbo ....................... 5-Speed Transaxle (F5MC1)\
2.0L Turbo ........................... 5-Speed Transaxle (F5M33)\
2.4L ................................. 5-Speed Transaxle (F5M31)\
Galant ................................... 5-Speed Transaxle (F5M31)\
Mirage
1.5L ................................... 5-Speed Transaxle (F5M41)\
1.8L ................................... 5-Speed Transaxle (F5M42)\
Montero
2WD ................................. 5-Speed Transmission (R5M21)\
4WD ................................. 5-Speed Transmission (V5MT1)\
3000GT
SOHC & DOHC Non-Turbo .................. 5-Speed Transaxle (F5M33)\
DOHC Turbo ............................. 6-Speed Transaxle (W6MG1)\
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LUBRICATION
SERVICE INTERVALS
Check transaxle/transmission and transfer case fluid level
every 30,000 miles. Change fluid at 30,000 miles if operated under
severe conditions.
CHECKING FLUID LEVEL
Transaxle/Transmission
Check fluid level at fill hole on side of transaxle or
transmission. Lubricant must be at bottom of fill hole.
Transfer Case
Transfer case contains separate drain and fill plugs.
Lubricant must be at bottom of fill hole.
RECOMMENDED FLUID
Transaxle/Transmission
Use API classification GL-4 or higher SAE 75W-85W gear oil.
Transfer Case
Use API classification GL-4 or higher SAE 75W-85W gear oil.
FLUID CAPACITIES
TRANSAXLE/TRANSMISSION REFILL CAPACITIES
Page 1365 of 1501
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Application Pts. (L)\
Eclipse
2.0L ................................................... 4.2 (2.0)\
2.0L Turbo ............................................. 4.9 (2.3)\
2.4L ................................................... 4.9 (2.3)\
Galant ................................................... 4.6 (2.2)\
Mirage
1.5L ................................................... 4.4 (2.1)\
1.8L ................................................... 4.6 (2.2)\
Montero
2.4L ................................................... 4.9 (2.3)\
3.0L ................................................... 5.3 (2.5)\
3000GT
Non-Turbo .............................................. 4.2 (2.0)\
Turbo .................................................. 5.0 (2.4)\
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TRANSFER CASE REFILL CAPACITIES \
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Application Pts. (L)\
Eclipse .................................................. 1.1 (0.5)\
Montero
2.4L ................................................... 5.3 (2.5)\
3.0L ................................................... 4.9 (2.3)\
3000GT ................................................... 1.3 (0.6)\
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Except Montero 4WD
Transfer Case Drain Plug & Filler Plug ................... 24 (33)\
Transmission Drain Plug & Filler Plug .................... 24 (33)\
Montero 4WD
Transfer Case Drain Plug & Filler Plug ................... 24 (33)\
Transmission Drain Plug & Filler Plug .................... 51 (69)\
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Page 1366 of 1501
TROUBLE SHOOTING - BASIC PROCEDURES
1998 Mitsubishi Montero
GENERAL TROUBLE SHOOTING
* PLEASE READ THIS FIRST *
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
ACCESSORIES & ELECTRICAL
CHARGING SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Vehicle Will Not Dead battery Check battery cells,
Start alternator belt
tension and alternator
output
Loose or corroded battery Check all charging
connections system connections
Ignition circuit or switch Check and replace as
malfunction necessary
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Alternator Light Loose or worn alternator Check alternator drive
Stays On With drive belt tension and
Engine Running condition, See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Loose alternator wiring Check all charging
connections system connections
Short in alternator light See Indicator Warning
wiring Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
Defective alternator stator See Bench Tests in
or diodes ALTERNATOR article
Defective regulator See Regulator Check in
Page 1367 of 1501
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ALTERNATOR article \
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Alternator Blown fuse See WIRING DIAGRAMS
Light Stays Off
With Ignition
Switch ON
Defective alternator See Testing in
ALTERNATOR article
Defective indicator light See Indicator Warning
bulb or socket Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
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Alternator Short in alternator wiring See On-Vehicle Tests
Light Stays OFF in ALTERNATOR article
With Ignition
Switch ON
Defective rectifier bridge See Bench Tests in
ALTERNATOR article
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Lights or Fuses Defective alternator wiring See On-Vehicle Tests
Burn Out in ALTERNATOR article
Frequently
Defective regulator See Regulator Check in
ALTERNATOR article
Defective battery Check and replace as
necessary
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Ammeter Gauge Loose or worn drive belt Check alternator drive
Shows Discharge belt tension and
condition. See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Defective wiring Check all wires and
wire connections
Defective alternator or See Bench Tests and
regulator On-Vehicle Tests in
ALTERNATOR article
Defective ammeter, or See Testing in
improper ammeter wiring STANDARD INSTRUMENTS
connection in the ACCESSORIES &
EQUIPMENT section
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Noisy Loose drive pulley Tighten drive pulley
Alternator attaching nut
Loose mounting bolts Tighten all alternator
mounting bolts
Worn or dirty bearings See Bearing
Replacement
ALTERNATOR article
Page 1368 of 1501
![MITSUBISHI MONTERO 1998 Service Manual Defective diodes or stator See Bench Test in
ALTERNATOR article
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ALTERNATOR article
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Defective diodes or stator See Bench Test in
ALTERNATOR article
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Battery Does Loose or worn drive belt Check alternator drive
Stay Charged belt tension and
condition. See
Belt Adjustment in
appropriate TUNE-UP
article in the
TUNE-UP section
Loose or corroded battery Check all charging
connections system connections
Loose alternator connections Check all charging
system connections
Defective alternator or See On-Vehicle Tests
battery and Bench Tests in
ALTERNATOR article
Add-on electrical accessories Install larger
exceeding alternator capacity alternator
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Battery Defective battery Check alternator
Overcharged- output and repair as
Uses Too Much necessary
Water
Defective alternator See On-Vehicle Test and
Bench Tests in
ALTERNATOR article
Excessive alternator voltage Check alternator output
and repair as necessary
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IGNITION SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
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START: Visually inspect Spark Plug Wires, Coil Wires,
Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.
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OK NOT OK
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* To test secondary ignition * Repair or replace
system, modify a Spark Plug damaged components
by attaching a ground wire as necessary
to the body of the plug and
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Page 1369 of 1501
widening the gap to 1/4-3/8".
Disconnect spark plug wire
and insert test plug. Ground
plug, crank engine, and
check for spark.
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GOOD SPARK NO SPARK
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* If plug sparks, driveability * Remove coil wire from the
problem is most likely NOT distributor and attach the
in the ignition system. modified spark plug. Ground
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the plug and crank engine
while checking for spark.
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GOOD SPARK NO SPARK
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* If plug has a good spark, * Proceed to the IGNITION
the problem is in the plug PRIMARY TROUBLE SHOOTING
wires, distributor cap, or CHECK CHART below in this
rotor. Replace components article.
as necessary.
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Ignition Primary Trouble Shooting Chart
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START: Visually inspect primary ignition wires for
broken, frayed, split, or cut wires. Also check
for loose, corroded, or disconnected connectors.
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* Check that battery voltage * Repair or replace damaged
is at least 11.5 volts. components as necessary.
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* Replace or recharge the * Check for battery voltage
battery. at the positive terminal of
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the coil.
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* Check air Gap of the Pick-Up * Check resistance of ballast
coil in the distributor. resistor (if used) for the
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correct resistance value.
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* Check Pick-Up coil for * Adjust or replace as
correct resistance value. necessary.
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NOT OK OK
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* Replace Pick-Up coil if * Check control module for
not to specification. good ground connections.
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OK
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* If vehicle fails to run at this point, go to
the appropriate article in the ENGINE
PERFORMANCE section.
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OK NOT OK
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* Check wires from the battery/ * Replace ballast resistor
ignition switch to the coil. if the measured resistance
Also check the coil primary value is not within
and secondary resistance. specification.
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STARTER TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Starter Fails Dead battery or bad Check battery charge
to Operate connections between and all wires and
starter and battery connections to starter
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article