MITSUBISHI MONTERO 1998 Service Manual

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert a clutch alignment tool to prevent
pressure plate and clutch disc from dropping. Loosen pressure plate
bolts gradually in a crisscross pattern to avoid warping pressure
plate flange during removal. Remove pressure plate and clutch disc.
See Fig. 3 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

DO NOT clean release bearing assembly in solvent. Inspect hydraulic
system components for fluid leakage. Inspect cylinder dust boot for
cracks or deterioration.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure depth from
clutch disc surface to head of rivet. Replace clutch disc if
measurement is less than .012" (.30 mm). See Fig. 4. Replace worn or
defective components as necessary.
Fig. 4: Measuring Clutch Disc (Typical)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS .
2) Clean release bearing sliding surface. Apply a light
coating of multipurpose grease to release bearing sliding surface.

Apply a very light coating of grease to input shaft splines. DO NOT
allow grease or dirt on clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
CLUTCH RELEASE BEARING & RELEASE FORK
Removal (2WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
clips, release bearing and carrier. Use a punch to remove shift arm
spring pin and release lever assembly. Remove shift arm, felt packing
and 2 return springs. See Fig. 5.
2) Ensure release bearing turns freely and smoothly under
light load. Replace bearing if noise, roughness or dryness is present.
DO NOT clean bearing in solvent. Use shop towel or compressed air
only.
Installation
1) Insert lever and shaft into left side of transmission
case. Place shift arm, felt packing and return springs on shaft
assembly. Apply grease to inside of bushing and oil seal lips. Apply
oil to felt packing.
2) Align shift arm pin and control shaft pin holes. Drive
spring pins into position, with slit area upward. Reverse removal
procedure to complete installation. Check pedal height and free play.
Adjust if necessary. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS.
Removal (4WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
spring or clips, and remove release bearing.
2) Slide release fork toward outside of transmission and
disengage from fulcrum ball. DO NOT slide release fork toward inside
of case, or damage to fulcrum ball clip will result. Remove release
fork boot.
Installation
To install, reverse removal procedure. Apply grease to
fulcrum ball contact area of release fork before installing. Fill
groove of release bearing inside diameter with grease before
installing. See Fig. 5.

Fig. 5: Exploded View Of Clutch Release Bearing & Shift Arm Assembly
Courtesy of Mitsubishi Motor Sales of America.
CLUTCH MASTER CYLINDER

Removal & Installation
1) Drain master cylinder. Remove cotter pin, washer and
clevis pin. Disconnect push rod from clutch pedal. Remove and plug
hydraulic line at clutch master cylinder.
2) Remove retaining nuts, clutch master cylinder and gasket.
To install, reverse removal procedure. Apply grease to clevis pin
before installing. Fill reservoir and bleed clutch system. See
BLEEDING CLUTCH HYDRAULIC SYSTEM .
CLUTCH RELEASE CYLINDER
Removal & Installation
Remove and plug hydraulic line at release cylinder. Remove
cylinder-to-transmission bolts. Remove clutch release cylinder. To
install, reverse removal procedure. Apply grease to push rod-to-
release fork contact area. Bleed clutch system. See
BLEEDING CLUTCH HYDRAULIC SYSTEM .
BLEEDING CLUTCH HYDRAULIC SYSTEM
Attach hose to bleeder fitting located on clutch release
cylinder, next to hydraulic line. Submerge other end of hose in
container half full of clean brake fluid. Fill reservoir with brake
fluid. Open bleeder fitting. Have assistant press clutch pedal to full
release position. Close bleeder fitting. Release clutch pedal. Repeat
until air bubbles no longer emerge from hose. Refill reservoir.
OVERHAUL
CLUTCH MASTER CYLINDER
NOTE: DO NOT disassemble piston assembly.
Disassembly
Remove piston stop ring, damper and push rod assembly. See
Fig. 6 . Remove piston assembly. Note position of reservoir band for
reassembly reference. Remove reservoir.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. On
Montero, adjust clutch master cylinder push rod to 5.90" (150 mm). On
Montero Sport, push rod adjustment is correct after adjusting clutch
pedal free play and pedal height. See CLUTCH PEDAL FREE PLAY and
CLUTCH PEDAL HEIGHT under ADJUSTMENTS. To reassemble, reverse
disassembly procedure. Ensure piston moves freely in bore.
Fig. 6: Exploded View Of Clutch Master Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.

CLUTCH RELEASE CYLINDER
Disassembly
Remove valve plate and spring. See Fig. 7. Remove push rod
and boot. Cover piston assembly opening with a rag. Slowly apply air
pressure to hydraulic line opening to force piston from body.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. To
reassemble, reverse disassembly procedure. Ensure piston moves freely
in bore.
Fig. 7: Exploded View Of Clutch Release Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Clutch Pedal Position Switch Adjusting Nut Or Bolt ......... 10 (13)\
Bellhousing-To-Engine Mounting Bolt
Montero
10 x 40 mm ............................................. 26 (36)\
10 x 55 mm ............................................. 22 (31)\
12 x 40 mm ............................................. 54 (75)\
12 x 55 mm ............................................. 65 (90)\
Montero Sport
2WD .................................................... 19 (26)\
4WD .................................................... 55 (75)\
Clutch Master Cylinder Mounting Nut ........................ 10 (13)\

Clutch Pedal Mounting Nut .................................. 21 (29)\
Flywheel Bolt
Montero .................................................. 54 (74)\
Montero Sport ........................................... 98 (132)\
Fulcrum Ball ............................................... 26 (35)\
Hydraulic Line Flare Nut ................................... 11 (15)\
Push Rod Jam Nut ........................................... 10 (13)\
Release Cylinder Mounting Bolt ............................. 27 (36)\
Starter Mounting Bolt ...................................... 23 (31)\
Transfer Case Roll Stopper Bolt ............................ 33 (44)\
Transmission Crossmember Mounting Bolt ..................... 47 (64)\
Transmission Support Bolt
Front (Crossmember) ...................................... 29 (39\
)
Rear ..................................................... 26 (35)\









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COMPUTER RELEARN PROCEDURES
1998 Mitsubishi Montero
GENERAL INFORMATION
Computer Relearn Procedures
All Models
* PLEASE READ THIS FIRST *
The following general procedures are to be used if
driveability problems are encountered after power loss or battery has
been disconnected. These procedures may provide an aid in eliminating
these problems.
To reduce the possibility of complaints, after any service
which requires battery power to be disconnected, vehicle should be
road tested.
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may
require a relearn procedure after vehicle battery is disconnected.
Many vehicle computers memorize and store vehicle operation patterns
for optimum driveability and performance. When vehicle battery is
disconnected, this memory is lost. The computer will use default data
until new data from each key start is stored. As computer memorizes
vehicle operation for each new key start, driveability is restored.
Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during
relearn stage because vehicle acts differently then before being
serviced. Depending on type and make of vehicle and how it is
equipped, the following complaints (driveability problems) may exist:
* Harsh Or Poor Shift Quality
* Rough Or Unstable Idle
* Hesitation Or Stumble
* Rich Or Lean Running
* Poor Fuel Mileage
These symptoms and complaints should disappear after a number
of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be
disconnected, vehicle should be road tested. If a specific relearn
procedure is not available, the following procedure may be used:
Automatic Transmission
* Set parking brake, start engine in "P" or "N" position.
Warm-up vehicle to normal operating temperature or until
cooling fan cycles.
* Allow vehicle to idle for one minute in "N" position. Select
"D" and allow engine to idle for one minute.
* Accelerate at normal throttle position (20-50%) until vehicle
shifts into top gear.
* Cruise at light to medium throttle.
* Decelerate to a stop, allowing vehicle to downshift, and use
brakes normally.
* Process may be repeated as necessary.
Manual Transmission

* Place transmission in Neutral position.
* Ensure emergency brake has been set and all accessories
are turned off.
* Start engine and bring to normal operating temperature.
* Allow vehicle to idle in Neutral for one minute.
* Initial relearn is complete: process will be completed during
normal driving.
Some manufacturers identify a specific relearn procedure
which will help establish suitable driveability during relearn stage.
These procedures are especially important if vehicle is equipped with
and electronically controlled automatic transmission or transaxle.
Always complete procedure before returning vehicle to customer.

COOLING SYSTEM SPECIFICATIONS & ENGINE COOLING FANS
1998 Mitsubishi Montero
1997-98 ENGINE COOLING
Mitsubishi Specifications & Electric Cooling Fans
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
SPECIFICATIONS
BELT ADJUSTMENT
NOTE: Use illustration for water pump drive belt routing. See
Figs. 1-6. The terms alternator and generator are used
interchangeably.
BELT ADJUSTMENT









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Application Deflection (1) In. (mm)
Diamante ....................................................... ( 2)
Eclipse & Galant
2.0L Non-Turbo ............................................... ( 2)
2.0L Turbo & 2.4L
Generator & Water Pump .................... 0.35-0.45 (9.0-11.4)\
Water Pump & Power Steering ................ 0.22-0.32 (5.6-8.1)\
Mirage
1.5L ........................................ 0.34-0.45 (8.6-11.4)\
1.8L ......................................................... ( 2)
Montero
A/C .......................................... 0.26-0.30 (6.6-7.6)\
Generator & Water Pump ................... ( 3) 0.22-0.26 (5.6-6.6)
Water Pump & Power Steering ................ 0.54-0.70 (13.7-17.8)\
Montero Sport
2.4L
A/C ........................................ 0.24-0.26 (6.1-6.6)\
Generator & Water Pump ................. ( 4) 0.28-0.35 (7.1-8.9)
Water Pump & Power Steering ................ 0.22-0.30 (5.6-7.6)\
3.0L
A/C ........................................ 0.22-0.26 (5.6-6.6)\
Generator & Water Pump ................. ( 3) 0.20-0.27 (5.1-6.8)
Water Pump & Power Steering .............. 0.52-0.68 (13.2-17.3)\
3000GT ......................................................... ( 3)
( 1) - With 22 lbs. (10 kg) pressure applied midway on belt run.
Values are for a used belt.
( 2) - Water pump is driven by timing belt. Timing belt deflection is
controlled by timing belt automatic tensioner.
( 3) - Measured between water pump pulley and crankshaft pulley.
( 4) - Measured between water pump pulley and generator pulley.









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