bolts MITSUBISHI MONTERO 1998 Manual PDF
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 1154 of 1501
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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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-
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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
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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.
Page 1162 of 1501
cross shaft and rack piston for wear and damage. Check contact part of
adjusting bolt for uneven wear. Check dust seal, oil seal and "O"
rings for wear and damage.
Reassembly
1) Install NEW cross shaft lower "U" packing (if removed).
Press lower cross shaft oil seal into gearbox housing. See Fig. 3.
Press bearing and oil seal into top cover. Install bearing race and
"O" ring.
2) Apply transmission fluid to seal ring contact areas on
mainshaft, and install seal rings firmly into valve grooves. Wrap
serrated part of mainshaft with vinyl tape. Mount valve body to valve
housing. Install cage and align hole in cage with channel in
mainshaft. Install bearing race and insert balls.
3) Install mainshaft into valve housing while pressing on
bearing race to prevent balls from falling out. Using spanner wrench,
install lock nut and tighten until it contacts bearing race.
4) Tighten lock nut while measuring mainshaft endplay using
dial indicator. When mainshaft endplay is .001" (.003 mm), use a punch\
to crimp circumference of lock nut. Ensure mainshaft rotates freely.
5) Apply transmission fluid to "O" ring and piston seal ring,
and install into gearbox housing. Install rack piston until it
contacts edge of mainshaft. Rotate mainshaft to align ball raceway
with insertion hole. Install 19 balls.
NOTE: Insert balls so no clearance exists between balls.
6) Place remaining 7 balls in circulator and install
circulator to rack piston. Install circulator holder. Install NEW
cross shaft upper "U" packing (if removed). Install upper cross shaft
"O" ring. Apply transmission fluid to rack piston seal ring and insert
valve housing. Rotate mainshaft until rack piston is centered (neutral
position).
7) Install adjusting plate so beveled part is facing upward.
Using a feeler gauge, measure clearance between adjusting bolt and
cross shaft. If clearance is greater than .002" (.05 mm), replace with\
appropriate adjusting plate.
8) Apply multipurpose grease to seal surface of "U" packing.
Apply transmission fluid to cross shaft teeth and side cover "O" ring.
Install cross shaft to side cover, and temporarily tighten adjusting
bolt lock nut.
CAUTION: DO NOT rotate side cover during installation, or damage to
cross shaft oil seal may result.
9) Apply transmission fluid to rack piston teeth and shaft
areas. Apply multipurpose grease to oil seal lip. Install side cover
assembly (with cross shaft) to gearbox.
10) Position mainshaft in straight-ahead position. While
turning adjusting bolt, measure mainshaft combined starting torque
using Preload Socket (MB990228-01) and an INCH-lb. torque wrench.
Combined starting torque should be 4-11 INCH lbs. (.5-1.3 N.m). Center\
reading should be 2 INCH lbs. (.2 N.m) higher than reading at either
end.
11) Tighten adjusting bolt lock nut to specification. See
TORQUE SPECIFICATIONS . Install pitman arm with mating marks aligned.
POWER STEERING PUMP
Disassembly
1) Remove suction connector bolts. Mount pump in a soft-jawed
vise. Remove pump cover bolts and cover. Using a plastic mallet, tap
pulley assembly shaft from pump housing. See Fig. 4.
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damage. Inspect groove of rotor vane and cam surface for stepped wear.
Check vane for damage. Install vane into rotor groove. Measure
clearance between vane and rotor groove. If clearance exceeds .0024"
(.061 mm), replace entire assembly.
2) Check ring and rotor sides for damage. Replace entire
assembly if any damage is present. Check sliding surfaces of control
valve for obstructions. Replace parts as required. If control valve is
replaced, always use valve with same identification mark as one being
replaced. Check power steering fluid pressure.
Reassembly
1) Lubricate "O" rings and internal pump components with ATF
before reassembly. Install flow control valve spring and control valve
in housing.
2) Install and tighten pressure connector. Depress control
valve to check for smooth operation. Apply grease to lip of oil seal.
Install oil seal into pump body. Install pulley assembly into pump
body.
3) Install rotor to pulley assembly with punch mark at pump
cover side. Install snap ring. Lift rotor to ensure that snap ring is
in countersunk part of shaft. Align cam ring dowel holes and install
cam ring with punch mark on pump body side.
4) Apply transmission fluid to vanes, and install vanes onto
rotor with rounded edges outward. Install "O" ring, cam case and pump
cover. Install and tighten suction connector.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Adjusting Bolt Lock Nut .................................... 27 (37)\
Idler Arm Bracket-To-Frame Bolt & Nut
Montero ............................................ 40-47 (54-64)\
Montero Sport ............................................ 43 (59)\
Idler Arm-To-Bracket Lock Nut ............................. 101 (44)\
Oil Pump Cover Bolts ....................................... 15 (20)\
Pitman Arm-To-Cross Shaft Nut
Montero ........................................ 108-123 (146-176)\
Montero Sport .................................. 108-123 (147-167)\
Pressure Hose In-Line Fitting
Montero .................................................. 25 (34)\
Montero Sport ............................................ 16 (22)\
Relay Rod-To-Idler Arm Nut ................................. 33 (44)\
Relay Rod-To-Pitman Arm Nut ................................ 33 (44)\
Side Cover Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (50-64)\
Steering Gear Hose Fittings ................................ 11 (15)\
Steering Gear-To-Frame Bolts ......................... 40-47 (54-64)\
Tie Rod Adjusting Sleeve Lock Nuts ......................... 69 (93)\
Tie Rod End Castle Nuts .................................... 33 (44)\
Valve Housing Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (56-64)\
Valve Housing Lock Nut ......................................... ( 1)
( 1) - Tighten lock nut until it contacts bearing race.
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Page 1226 of 1501
DRIVE CABLES
NOTE: Drive cable removal and installation information for 3000GT
not available from manufacturer at time of publication.
Removal & Installation (Eclipse & Galant)
1) Remove sliding roof assembly. See SUN ROOF R & I under
REMOVAL & INSTALLATION. Remove sun shade and stopper at rear end of
drive rail. Remove sliding roof drive cable assembly from rear part of
guide rail. Depress assembly into guide rail to slide past notches if
necessary.
2) Once sliding assembly is removed, DO NOT lose plastic
sliding shoes attached to assembly. Ensure guide rail, sliding
assembly and drive cables are clean before reassembly.
3) To install components, reverse removal procedure. Apply
multipurpose grease to all moving components. To install sliding roof
assembly, reverse removal procedure.
Removal & Installation (Montero)
1) Remove sliding roof assembly. See SUN ROOF R & I under
REMOVAL & INSTALLATION. Remove plastic mounting cover and roof glass
panel. Remove front guide bracket and deflector assembly. Remove front
guide rail end cover. Remove set plate and guide rail assembly. Remove
sun shade and drive cable tube. Remove lifter assembly and slider
assembly from housing assembly.
2) Ensure guide rail, sliding assembly and drive cables are
clean before installation. To install components, reverse removal
procedure. Apply multipurpose grease to all moving components. To
install sliding roof assembly, reverse removal procedure.
Removal & Installation (Montero Sport)
Tilt sun roof guide assembly. Remove sun roof guide rail rod
holder. Close sun roof guide assembly and disconnect drive cable end
from sun roof guide assembly. To install components, reverse removal
procedure. Always replace cables in pairs. Apply multipurpose grease
to all moving components.
DRIVE MOTOR R & I
Removal (Eclipse & Galant)
1) To remove sun roof drive motor, lower headliner enough to
gain access to motor. Remove overhead switch assembly. Remove front
and rear door scuff plate.
2) Remove center pillar lower and upper trim. Remove roof
rail and sun roof trim strips. Remove front pillar trim. Remove assist
handle (if necessary). Lower headliner to gain access to motor
assembly. Disconnect motor harness connector. Remove motor mounting
bolts and remove motor.
Inspection
Check each drive gear tooth for abrasion or wear. Check both
drive cables for wear. Replace as necessary.
Installation
Ensure sun roof glass panel is fully closed. Sun roof drive
cables must be properly indexed to drive motor drive gear. Remove
drive motor cam gear cover. Using crank handle (included in tool
pouch), rotate motor to correct position. For Galant, see Fig. 12.
Install motor. To complete installation, reverse removal procedure.
Removal & Installation (Montero)
Remove sun roof switch assembly. Remove drive motor. To
Page 1228 of 1501
SUN ROOF R & I
Removal & Installation (Eclipse & Galant)
1) Remove side trim covers by lightly pulling panels straight
down. Unbolt and remove roof glass panel with adjust plates. See
Fig. 1 . Operate sun roof drive cable assembly to fully open position.
Remove deflector. Remove guide rail cover. Operate sun roof drive
cable assembly to fully closed position and remove rear drip channel.
2) Remove overhead switch assembly. Remove rear seat. Push
down on rear seat cushion and pull seat release lever. Unbolt and
remove seat back. Remove front and rear door scuff plate.
3) Remove center pillar lower and upper trim. Remove roof
rail and sun roof trim strips. Remove front and rear pillar trim.
Remove assist handle. Remove headliner. Disconnect motor harness
connector. Remove motor mounting bolts and remove motor.
4) Attach protective tape around roof opening. Pull sliding
roof assembly forward through roof opening. Disconnect drain hoses. If
drain hoses need replacement, attach cord to exterior end of drain
hose. Pull drain hose from interior end. Remove housing assembly and
set brackets.
5) To install components, reverse removal procedure. Sun roof
drive cables must be properly indexed to drive motor drive gear.
Remove drive motor cam gear cover. Using manual closure wrench
(included in tool pouch), rotate motor to correct position. See
Fig. 12 . Install motor. Install remaining components. To adjust roof
glass panel, see SUN ROOF GLASS FIT under ADJUSTMENTS.
Removal & Installation (Montero)
1) Remove trim covers. Unbolt roof glass panel from sliding
assembly and remove. Remove sun roof switch assembly and drive motor.
Remove front and rear door scuff plate.
2) Remove center pillar lower and upper trim. Remove roof
rail and sun roof trim strips. Remove front and rear pillar trim.
Remove assist handle. Remove headliner. Remove rear set bracket.
Remove sun roof assembly. Disconnect drain hoses.
3) If drain hoses need replacement, attach cord to exterior
end of drain hose. Pull drain hose from interior end. To install
components, reverse removal procedure. See DRIVE MOTOR R & I for
installation procedures.
Removal & Installation (Montero Sport & 3000GT)
Remove sun roof switch and dome light assembly. Remove
bracket behind dome light. Remove headliner. Remove drain hose
retaining clips and remove drain hose. Remove sun roof assembly. To
install, reverse removal procedure.
WIRING DIAGRAMS
Page 1237 of 1501
seal and spacer from steering knuckle.
Inspection
Inspect steering knuckle for cracks. Inspect spindle for wear
and heat damage.
Installation
1) If needle bearing needs replacement, drive bearing from
steering knuckle. Use Bearing Driver (MB990956-01) and Handle
(MB9909938-01) to install NEW needle bearing until it is even with
steering knuckle end face.
NOTE: DO NOT reuse steering knuckle needle bearing if it is
removed.
2) Lubricate bearing roller surface and spacer-to-steering
knuckle contact areas. Install spacer with chamfered side toward
inside of vehicle. Using Seal Installer (MB990985-01) and handle,
install seal in steering knuckle until seal is even with steering
knuckle end face. Apply grease to seal lip area and inside of seal. To
complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
LOWER BALL JOINT
Removal
1) Raise and support vehicle. Remove skid plate (if
equipped). Remove wheel assembly. Mark torsion bar adjusting nut for
reassembly reference. Release torsion bar tension.
2) Loosen, but DO NOT remove, lower ball joint stud nut.
Using Steering Linkage Puller (MB991406), separate ball joint from
steering knuckle. Remove ball joint stud nut. Remove ball joint-to-
lower control arm bolts. Remove ball joint.
Installation
Lubricate ball joint. To complete installation, reverse
removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS .
LOWER CONTROL ARM
Removal
1) Raise and support vehicle. Remove wheel assembly. Remove
front skid plate and undercover (if equipped). Remove bump stop and
bump stop bracket. Remove heat shield (if equipped). Remove torsion
bar. See TORSION BAR . Loosen, but DO NOT remove, lower ball joint-to-
steering knuckle nut. Using Steering Linkage Puller (MB991406),
separate lower ball joint from steering knuckle. Support with cord
tied to nearby part.
2) Remove stabilizer bar bolt from control arm. Remove shock
absorber mounting bolts. Remove ball joint stud nut from steering
knuckle. Remove control arm shaft. See Fig. 1. Remove torque arm.
Remove bump stopper and lower control arm. Remove lower ball joint
from lower control arm.
Inspection
1) Inspect control arm for cracks and deformation. Check ball
joints. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION.
2) Inspect ball joint dust covers for damage. Replace damaged
dust covers. Inspect control arm bushing and frame bracket bushing for
damage. Replace bushings if necessary.
NOTE: Differential carrier may require detachment in order to
Page 1238 of 1501
replace left bracket bushing.
NOTE: Tighten lower control arm shaft and pivot bolt to
specification with vehicle at normal operating height.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Tighten lower control arm
shaft and pivot bolt to specification with vehicle at normal operating
height.
STABILIZER BAR
Removal
Remove skid plate (if equipped). Disconnect stabilizer bar
link bolt. Remove stabilizer bar clamp bolts. Remove stabilizer bar
and bushings. On Montero Sport remove the stabilizer link brackets and
bushings.
Installation
1) To install, reverse removal procedure. Note that slit in
stabilizer bushing faces vehicle. Marks on bar should be approximately
0.39" (10 mm) from edge of bracket. On Montero Sport adjust the
stabilizer link assembly mounting nut so there is 0.2-0.3" (6-8 mm) of\
threads exposed from the top of the nut to the top of the threads.
TORSION BAR
NOTE: Mark torsion bar and anchor arm location for reassembly
reference before removing.
Removal
1) Raise and support vehicle. Support lower control arm using
jack stand. Loosen anchor arm adjusting bolt lock nut. Remove heat
protector from frame (right side only). Loosen anchor arm bolt to
release torsion bar tension.
2) Mark front of torsion bar and torque arm for reassembly
reference. Remove anchor arm. See Fig. 1. Remove dust covers from
torsion bar. Remove heat cover (right side only) located between dust
cover and torsion bar. Remove torsion bar.
Inspection
Inspect all splined areas for damage. Inspect dust covers for
cracks and damage. Check for bent anchor arm bolts. Replace components
as necessary.
Installation
1) Apply grease to splined areas of torsion bar, anchor arm,
torque arm splines, anchor arm bolt threads and inside of dust cover.
Check for left and right identification marks on torsion bar ends.
Ensure torsion bars are installed in correct locations.
2) Install torsion bar in torque arm, with identification
mark toward front of vehicle and the slit in the anchor collar facing
downward. Align mark on torque arm with mating mark on torsion bar.
When installing a new torsion bar, align White paint spline with index
mark on front anchor arm.
3) Tighten anchor arm bolt adjusting nut to obtain correct
final bolt protrusion. See FINAL ANCHOR ARM BOLT PROTRUSION table.
Final bolt protrusion depends upon curb weight of vehicle. With
vehicle unladen, measure distance from bump stopper bracket to bump
stopper. Distance should be 0.83-0.91" (21-23 mm) on Montero, 0.7" (1\
8
mm) on Montero Sport. If not, adjust anchor bolt nut.