bolts MITSUBISHI MONTERO 1998 Owner's Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 243 of 1501
![MITSUBISHI MONTERO 1998 Owners Manual Front .................................................... 66 (90)\
Rear .................................................... 94 (127)\
Wheel Lug Nut
15x6" Wheel .........................](/img/19/57333/w960_57333-242.png "MITSUBISHI MONTERO 1998 Owners Manual Front .................................................... 66 (90)\
Rear .................................................... 94 (127)\
Wheel Lug Nut
15x6\" Wheel .........................")
Front .................................................... 66 (90)\
Rear .................................................... 94 (127)\
Wheel Lug Nut
15x6" Wheel ..................................... 87-101 (118-137)\
15x7" Wheel ....................................... 72-86 (98-117)\
Rear Axle Bearing Retainer Nut ................... 145-173 (196-235)\
INCH Lbs. (N.m)
Master Cylinder Mounting Nut .............................. 115 (13)\
Bleeder Screw ............................................... 71 (8)\
Wheel Cylinder Nut ......................................... 89 (10)\
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TORQUE SPECIFICATIONS (3000GT) \
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Application Ft. Lbs. (N.m)\
Brake Line Flare Nuts ...................................... 11 (15)\
Caliper Guide & Lock Pin Bolt (FWD)
Front .................................................... 54 (73)\
Rear ..................................................... 20 (27)\
Caliper Mounting Bolts
Front .................................................... 66 (90)\
Rear ............................................... 36-43 (49-59)\
Front Axle Shaft Nut ..................................... 166 (230)\
Rear Wheel Bearing Nut
AWD ............................................ 192-221 (260-300)\
FWD .................................................... 170 (230)\
INCH Lbs. (N.m)
Master Cylinder Mounting Nut ............................... 84 (10)\
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BRAKE SYSTEM BRAKE SPECIFICATIONS
BRAKE SPECIFICATIONS (DIAMANTE) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .016-.024 (.40-.60)\
Disc Runout ............................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum)
Front ................................................. 1.08 (2.0)\
Rear .................................................. 1.04 (1.0)\
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BRAKE SPECIFICATIONS (ECLIPSE) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .023-.033 (.65-.85)\
Disc Runout ............................................. .003 (.08)\
Disc Diameter
AWD .................................................... 9.0 (228)\
Except AWD ............................................. 8.0 (204)\
Page 260 of 1501
specified, bleed system and inspect hydraulic and clutch components.
See CLUTCH PEDAL SPECIFICATIONS table.
CLUTCH PEDAL INTERLOCK SWITCH
1) Place transmission in Neutral and apply parking brake.
Turn ignition switch to START position with clutch pedal not
depressed. Engine should not crank. If engine cranks, adjust or
replace interlock switch.
2) Disconnect interlock switch connector. Interlock switch
connector is located at clutch pedal. Depress and release interlock
switch. Using ohmmeter, check continuity between interlock switch
terminals. If continuity exists with interlock switch depressed and
does not exist with switch released, switch is okay. Adjust or replace
as necessary.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (2WD Models)
1) Disconnect negative battery cable. Remove shift knob, dust
cover retaining plate, gaskets, stopper plate and control lever
assembly. Raise and support vehicle.
2) Remove front exhaust pipe. Drain transmission fluid. Index
mark drive shaft flange and remove drive shaft.
3) Disconnect back-up light switch connector, speedometer
cable connection and exhaust pipe mounting bracket. Remove lower
bellhousing cover. Disconnect clutch cable from clutch lever.
4) Support transmission with jack. Remove rear engine mount
nuts and bolts from transmission. Remove crossmember with rear engine
mount. Remove remaining bellhousing bolts, move transmission toward
rear and lower from vehicle.
5) If reusing pressure plate, index mark pressure plate to
flywheel for installation reference. Install 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.
Inspection
1) Check release bearing and release fork for damage or wear.
DO NOT clean release bearing assembly in solvent.
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 distance
from clutch disc surface to head of rivet. Replace clutch disc if
distance is less than .012" (.30 mm). Replace worn or defective
components as necessary. See Fig. 4.
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. If reusing pressure plate, ensure index marks are
aligned. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS . See Fig. 3.
2) Clean release bearing sliding surface. DO NOT clean
Page 261 of 1501
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.
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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.
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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.
Page 361 of 1501
![MITSUBISHI MONTERO 1998 Owners Manual AXLE RATIO SPECIFICATIONS \
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Application")
AXLE RATIO SPECIFICATIONS \
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Application Ratio
Montero ..................................................... 4.27:1
Montero Sport .................................................. (1)
( 1) - On vehicles equipped with wide fender, ratio is 4.64:1. On
vehicles with narrow fender, ratio is 4.27:1.
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LUBRICATION
CAPACITY
DIFFERENTIAL FLUID CAPACITY \
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Application Specification
Montero & Montero Sport ............................ 2.4 Pts. (1.1L)\
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FLUID TYPE
All models use fluid type SAE 80W-90/API GL-5.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
AXLE SHAFTS R & I
Removal
1) Raise and support vehicle. Remove wheels and undercover.
Ensure hub is in free-wheeling position. Place transfer case in 2H
position. Remove drive hub cover, snap ring and shim from axle shaft.
See Fig. 3 . Remove brake calipers and support aside.
2) Disconnect tie rod assembly. Support lower control arm
with jack. Separate ball joints from knuckle. Remove knuckle and front
hub assembly. Using flat-blade pry bar, carefully remove left axle
shaft from differential carrier. DO NOT damage oil seal. On right axle
shaft, remove axle shaft-to-inner shaft flange retaining bolts. Remove
right axle shaft.
CAUTION: Replace circlips on BJ/DOJ splined shaft end.
Installation
1) Install right axle shaft on inner shaft flange. Install
new circlip on DOJ side of left axle shaft. Carefully install left
axle shaft into differential. DO NOT damage oil seal.
2) Reinstall knuckle with front hub assembly. To complete
installation, reverse removal procedure. Install shim and snap ring.
Check axle end play. See Fig. 4. End play should be .016-.028" (.4-.7
mm). If end play is not within specification, install correct shim.
Page 364 of 1501
tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Pack proper amount of grease in BJ and BJ boot. See
CV JOINT GREASE CAPACITY table. Boot bands must be installed so lever
is pulled toward rear of vehicle when band is tightened.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage. Apply
proper amount of grease to outer DOJ race. See
CV JOINT GREASE CAPACITY table. Install shaft into DOJ outer race.
Install circlip.
4) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between center line of boot
bands. Distance should be 3.03-3.27" (76.9-83.0 mm). This distance is
necessary to control air in DOJ boot. Tighten boot bands. Install boot
protector and band. Install dust cover on shaft.
CV JOINT GREASE CAPACITY
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Application ( 1) Ozs. (g)
BJ Boot & Joint
Montero ................................................ 4.6 (130)\
Montero Sport .......................................... 4.2 (120)\
DOJ Boot & Joint
Montero ................................................ 3.5 (100)\
Montero Sport .......................................... 4.9 (140)\
( 1) - Apply 1/2 of the amount of grease specified to joint, the other
half to inside of CV boot.
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DIFFERENTIAL ASSEMBLY
Disassembly
1) Remove differential carrier from vehicle. See
DIFFERENTIAL CARRIER ASSEMBLY under REMOVAL & INSTALLATION. Remove
cover. Mark bearing caps for reassembly reference. Remove bearing
caps. Remove differential case assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components
must be installed in original location.
2) Using bearing puller, remove differential case side
bearings. Loosen ring gear retaining bolts in diagonal sequence.
Remove ring gear. Remove drive pinion shaft lock pin from ring gear
side. Remove pinion shaft and pinion gears. Remove side gears and
thrust spacers.
Drive Pinion Removal
Remove pinion flange nut. Scribe alignment mark on pinion
companion flange and drive pinion. Remove flange. Using soft-faced
hammer, drive out pinion. Remove rear bearing and oil seal from
carrier. Remove rear adjusting shim from pinion. See Fig. 1. Press
front bearing from pinion. Remove front adjusting shim and spacer from
pinion.
Cleaning & Inspection
Use cleaning solvent to rinse gears and components. Check
bearings for wear or discoloration. Check gear carrier for cracks or
damage. Check pinion, side gear and flange splines for excessive wear.
Page 365 of 1501
Check ring gear, pinion and side gears for wear or damage. Replace
components as necessary.
Reassembly & Adjustments
1) Place side gear thrust spacers behind side gears, in
original position. Assemble side gears in differential case. Install
pinion gears and washers. Rotate pinion gears to mesh with side gears.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. Using
dial indicator, measure gear backlash. See Fig. 5.
3) Backlash must be within specification. See
PINION & SIDE GEAR BACKLASH SPECIFICATIONS table. Adjust backlash by
using different side gear spacers. Ensure both sides are equally
shimmed. If backlash cannot be adjusted within specifications, replace
side and pinion gears as matched set.
4) Install pinion shaft lock pin. Using a punch, securely
stake lock pin in 2 places. Ensure adhesive is removed from ring gear
mounting bolts and gear mounting surface. Clean internal threads with
tap.
5) Install ring gear on differential case. Ensure alignment
marks on differential case and ring gear are aligned. Apply Loctite
271 to bolts and install bolts. Tighten bolts alternately in diagonal
sequence to specification. See TORQUE SPECIFICATIONS.
PINION & SIDE GEAR BACKLASH SPECIFICATIONS
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Application In. (mm)\
Standard ................................................ .003 (.08)\
Wear Limit .............................................. .008 (.20)\
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Fig. 5: Checking Pinion & Side Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.
Drive Pinion Depth
1) Install pinion bearing races in carrier housing. Ensure
Page 367 of 1501
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion companion flange, washer and
retaining nut. Tighten nut to 137 ft. lbs. (190 N.m).
2) Using INCH-lb. torque wrench, check pinion rotating torque
without pinion oil seal. See PINION ROTATING TORQUE SPECIFICATIONS
table. Adjust rotating torque by replacing drive pinion front shims or
spacer. Once correct rotating torque is obtained, install oil seal.
Coat seal lip with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install NEW
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
Side Bearing Installation
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal in thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier housing.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges (feeler gauges 180 degrees opposed), measure clearance
between carrier and side bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add .002" (.05 mm) to\
50% of measured clearance and then add thickness measurement of
removed shim. This is thickness of new shim that should be installed
on each side of case. Install equal thickness shims on each side of
case assembly.
NOTE: Ensure zero clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Check ring gear backlash.
Ring Gear Backlash
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash should be .004-.006" (.10-.15 mm).
2) If backlash is not within specification, change side
bearing adjusting shims and recheck backlash. See
GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Check gear
tooth contact using Prussian Blue.
CAUTION: When changing shims, total thickness of all shims must
remain constant to ensure correct bearing preload.
Ring Gear Runout
Using dial indicator, measure runout at back side of ring
gear. Runout should not exceed .002" (.05 mm). If runout is excessive,\
change ring gear-to-differential case mounting position. Ensure ring
gear mounting bolts are tightened to correct specification. Recheck
runout. Install cover and gasket.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Page 368 of 1501
![MITSUBISHI MONTERO 1998 Owners Manual Brake Caliper Bolt ......................................... 65 (88)\
Carrier-To-Housing Tube Bolt
Montero ...................................................... (1)
Montero Sport ..........](/img/19/57333/w960_57333-367.png "MITSUBISHI MONTERO 1998 Owners Manual Brake Caliper Bolt ......................................... 65 (88)\
Carrier-To-Housing Tube Bolt
Montero ...................................................... (1)
Montero Sport ..........")
Brake Caliper Bolt ......................................... 65 (88)\
Carrier-To-Housing Tube Bolt
Montero ...................................................... (1)
Montero Sport ...................................... 58-72 (79-98)\
Differential
Cover Bolt ............................................... 14 (19)\
Drain Plug
Montero .......................................... 43-51 (58-69)\
Montero Sport .............................................. ( 1)
Fill Plug
Montero ................................................ 39 (53)\
Montero Sport .......................................... 36 (49)\
Drive Shaft Flange Bolt .............................. 36-43 (49-58)\
Front Crossmember Bolt .............................. 72-87 (98-118)\
Hub Cover Bolt ....................................... 13-25 (18-34)\
Knuckle-To-Ball Joint Nut
Upper
Montero ................................................ 54 (73)\
Montero Sport .................................... 44-65 (60-88)\
Lower
Montero .............................................. 108 (146)\
Montero Sport ............. .................. 87-130 (118-176)\
Mounting Bracket-To-Frame Bolt ...................... 58-80 (79-108)\
Mounting Bracket-To-Housing Tube Bolt ................ 58-72 (79-98)\
Pinion Flange Nut
Montero
A/T .................................................. 137 (186)\
M/T .................................................. 159 (216)\
Montero Sport .......................................... 159 (216)\
Right Drive Axle-To-Inner Shaft Bolt ................. 36-43 (49-58)\
Ring Gear-To-Case Bolt ............................... 58-65 (79-88)\
Side Bearing Cap Bolt ................................ 40-47 (54-64)\
Tie Rod-To-Knuckle Nut
Montero .................................................. 33 (45)\
Montero Sport ............................................ 32 (43)\
Wheel Lug Nuts
Montero ........................................... 72-87 (98-118)\
Montero Sport
Aluminum Wheel .................................. 73-86 (99-117)\
Steel Wheel ................................... 87-101 (118-137)\
INCH Lbs. (N.m)
Undercover-To-Frame Bolts (Montero) .............. 84-108 (9.5-12.2\
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( 1) - Information is not available from manufacturer.
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