brake MITSUBISHI MONTERO 1998 Repair Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 244 of 1501
![MITSUBISHI MONTERO 1998 Repair Manual Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Drum Inside Diameter (Maximum](/img/19/57333/w960_57333-243.png "MITSUBISHI MONTERO 1998 Repair Manual Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Drum Inside Diameter (Maximum")
Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Drum Inside Diameter (Maximum) ........................... 9.1 (231\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter
With ABS .............................................. 1.0 (25.4)\
Without ABS ........................................... .93 (23.8)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\
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BRAKE SPECIFICATIONS (GALANT) \
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Application In. (mm)\
Booster Pushrod Clearance
Single Booster ............................... .024-.031 (.60-.80)\
Tandem Booster ............................... .016-.024 (.40-.60)\
Disc Runout ............................................. .003 (.08)\
Disc Thickness (Minimum) ................................ .88 (22.4\
)
Drum Inside Diameter (Maximum) ........................... 9.1 (231\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\
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BRAKE SPECIFICATIONS (MIRAGE) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.033 (.65-.85)\
Disc Runout ........................................... .006 (.0024)\
Disc Thickness (Minimum) ................................ .65 (16.4\
)
Drum Inside Diameter (Maximum) ........................... 8.1 (206\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ........................ .87 (22.22)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\
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BRAKE SPECIFICATIONS (MONTERO) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.035 (.65-.90)\
Disc Runout
Front ................................................. .004 (.10)\
Rear .................................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. 1.0 (25.4)\
Rear .................................................. .65 (16.4)\
Hub End Play ........................................... .0098 (.25)\
Master Cylinder Inside Diameter ........................ .937 (23.8)\
Pad Lining Thickness (Minimum)
Front ................................................. 1.08 (2.0)\
Rear ........................................................ (1)
Parking Brake Drum Diameter (Maximum) .................. 7.795 (198\
)
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(1) - Information not available from manufacturer. \
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BRAKE SPECIFICATIONS (MONTERO SPORT) \
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Application In. (mm)\
Disc Runout
Front ................................................. .002 (.06)\
Rear .................................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear .................................................. .65 (16.4)\
Drum Diameter (Maximum) .............................. 10.71 (272.0\
)
Hub End Play (Maximum) .................................. .002 (.05\
)
Master Cylinder Inside Diameter ........................ .937 (23.8)\
Pad Lining Thickness (Minimum) .......................... 1.08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter .......................... .90 (22.8)\
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BRAKE SPECIFICATIONS (3000GT) \
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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.030 (.65-.75)\
Disc Runout
Front
AWD ................................................. .004 (.10)\
FWD ................................................. .003 (.07)\
Rear ................................................ .003 (.08)\
Disc Thickness (Minimum)
Front
AWD ................................................ 1.12 (28.4)\
FWD ................................................. .88 (22.4)\
Rear
AWD ............................................... .72 (18.4)\
FWD ............................................... .65 (16.4)\
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum) .......................... 1.08 (2.0\
)
Parking Brake Drum Diameter (Maximum) ................... 6.65 (169\
)
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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 265 of 1501
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 266 of 1501
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)\
Page 268 of 1501
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
Page 269 of 1501
* 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.
Page 299 of 1501
* PLEASE READ THIS FIRST *
NOTE: For further trouble shooting information, see INPUT
INSPECTION CHART. See Fig. 3. See
INSPECTION CHART FOR TROUBLE SYMPTOMS table under SYMPTOM
TESTS.
PRELIMINARY CHECKS
Inspect vacuum pump, linkage assembly, actuator, cables and
vacuum hoses. Ensure linkage and cables move smoothly. Ensure cables
do not have excessive slack or tension.
CRUISE CONTROL SWITCH FUNCTION TEST
NOTE: If vehicle speed decreases about 9 MPH less than the set
speed, set speed will be canceled. Speed will not set beyond
system limit of 124 MPH.
1) Cruise control switch is part of multifunction switch
mounted on steering column. To operate cruise control system, turn
ignition on. Turn cruise control switch to ON position. Ensure switch
indicator light comes on.
2) With cruise control switch in ON position, drive vehicle
at least 25 MPH. Press and release SET button. Vehicle speed should
stay at set speed. Instrument cluster cruise indicator light should
come on. To increase set speed, turn control switch to RESUME position
and hold until new set speed is reached.
3) To lower set speed, press SET button and hold until new
set speed is reached. To return to set speed after cancellation, move
resume switch to ON position. Vehicle speed should return to previous
setting before cancellation. Set speed should cancel when any of the
following occurs:
* Brake pedal is depressed.
* Cruise control main switch is turned to OFF position.
* Ignition switch is turned to OFF position.
* Transmission is shifted to Neutral.
SYSTEM CANCELS OR WILL NOT RESET AFTER CANCELLATION
1) Check for trouble codes. See RETRIEVING CODES under SELF-
DIAGNOSTIC SYSTEM. If no trouble codes are stored, ensure cruise
control can be set.
2) If cruise control can be set, system may have canceled due
to driving on steep hills, or a loose wiring connection. If cruise
control still cannot be set, perform SYSTEM INPUT TESTS under SYMPTOMS
TESTS.
3) If SYSTEM INPUT TESTS check okay, check vacuum pump
circuit. See CODE 11 under DIAGNOSTIC TESTS. If SYSTEM INPUT TESTS do
not check okay, see INPUT INSPECTION CHART. See Fig. 3.
SYMPTOM TESTS
SYSTEM INPUT TESTS
1) System input tests should be performed if no trouble codes
are stored when performing RETRIEVING CODES under SELF-DIAGNOSTIC
SYSTEM. System input tests cycle each cruise control switch and
sensor.
Page 300 of 1501
2) Use scan tool for system input check according to
operating instructions provided with scan tool. Connect leads of
analog voltmeter between cruise control terminal and ground terminal
of data link connector. See Fig. 35.
3) Turn ignition on. To display results of input check, move
cruise control SET switch to ON position. Then turn MAIN switch to ON
position. Within one second, activate RESUME switch. Codes will
display if circuit tested is okay. See Fig. 3.
Fig. 3: Input Inspection Chart
Courtesy of Mitsubishi Motor Sales of America
INSPECTION CHART FOR TROUBLE SYMPTOMS TABLE
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Trouble Symptom Perform Test No.
Communication With Scan Tool Not Possible
(Communication With All Systems Not Possible) ........ 1
Communication With Cruise Control ECU Not Possible ..... 2
Diagnostic Inspection Possible/Input Inspection
Not Possible ......................................... 3
Cruise Control Does Not Cancel
With Brake Pedal Depressed ........................... 4
With Select Lever In Neutral ......................... 5
With CANCEL Switch ON ................................ 6
Diagnosis Display Normal/Cruise Control Will Not Set ... 7
Cruise Control Cannot Be Set ........................... 8
Hunting Occurs At Set Speed ............................ 9
With Cruise Control Main Switch ON,
Switch Indicator Does Not Illuminate
(Cruise Control Operation Normal) .................. 10
Cruise Control Main Switch Illumination Light
Does Not Illuminate ................................. 11
Indicator Light Inside Combination Meter
Page 316 of 1501
harness, dash wiring harness and joint connector C-132. Repair as
necessary. If malfunction remains, check harness between cruise
control main switch and power supply. Repair as necessary.
5) Check condition of cruise control ECU connector C-50.
Repair as necessary. If connector is okay and malfunction persists,
replace cruise control ECU.
Test No. 3
Malfunction of cruise control main switch or cruise control
ECU ground circuit may be present. Probable causes are:
* Malfunction of cruise control main switch.
* Malfunction of clockspring.
* Malfunction of connector.
* Malfunction of harness.
1) Check cruise control switches. See
CRUISE CONTROL SWITCH TESTS under COMPONENT TESTS. Replace any failed
switch. If switches are okay, check clockspring. See CLOCKSPRING TEST
under COMPONENT TESTS. If clockspring is okay, go to next step.
Replace clockspring if not okay.
2) Disconnect clockspring connector C-128 and measure voltage
between terminal No. 2 and ground. See Fig. 15. If battery voltage is
present, go to next step. If battery voltage is not present, check
condition of IOD connector A-09X, joint connector C-131, junction
block connector C-81, junction block connector C-94 and junction block
connector C-101. Repair as necessary. See Figs. 4, 16, 19, 21, 22, 26,
27 and 29. If connectors are okay and malfunction remains, check
harness between clockspring and power supply. Repair as necessary.
3) Check condition of cruise control ECU connector C-50 and
clockspring connector C-128. Repair as necessary. See Figs. 13 and 15.
If connectors are okay and malfunction remains, check harness between
clockspring and cruise control ECU. Repair as necessary.
Test No. 4
Malfunction of stoplight switch or stoplight circuit may be
present. Probable causes are:
* Malfunction of stoplight switch.
* Malfunction of connector.
* Malfunction of harness.
* Malfunction of cruise control ECU.
1) If stoplight does not illuminate with brake pedal
depressed, go to next step. If stoplight illuminates with pedal
depressed, replace cruise control ECU.
2) Check stoplight switch. See
BRAKELIGHT/STOPLIGHT SWITCH TEST under COMPONENT TESTS. Replace
stoplight switch as necessary. If stoplight switch is okay, go to next
step.
3) Disconnect stoplight switch connector C-55. See Fig. 14.
At harness side of connector, measure voltage between terminal No. 2
and ground. If battery voltage is present, go to next step. If battery
voltage is not present, check condition of joint connector C-131 and
junction block connector C-94. Repair as necessary. See Fig. 26. If
connectors are okay and malfunction remains, check harness between
stoplight switch and power supply. Repair as necessary.
4) Check condition of cruise control ECU connector C-50 and
stoplight switch connector C-55. Repair as necessary. If connectors
are okay and malfunction remains, check harness between stoplight
switch and cruise control ECU. Repair as necessary.
Test No. 5