bolts MITSUBISHI MONTERO 1998 Manual Online
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Page 1239 of 1501
![MITSUBISHI MONTERO 1998 Manual Online FINAL ANCHOR ARM BOLT PROTRUSION \
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Application/")
FINAL ANCHOR ARM BOLT PROTRUSION \
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Application/ Right Bolt Left Bolt
Model In. (mm) In. (mm\
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Montero ................... 3.15 (80.0) .............. 3.15 (80.0\
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4) To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. Check
riding height and front wheel alignment. See WHEEL ALIGNMENT
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section.
UPPER BALL JOINT
Removal
1) Raise and support vehicle. Remove wheel assembly. Mark
torsion bar adjusting nut for reassembly reference. Release torsion
bar tension. Loosen, but DO NOT remove, upper ball joint-to-steering
knuckle nut.
2) Using Steering Linkage Puller (MB991406), separate ball
joint from steering knuckle. Remove ball joint nut from steering
knuckle. Remove ball joint-to-upper control arm bolts. Remove ball
joint.
Installation
Lubricate ball joint. To complete installation, reverse
removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS .
SHOCK ABSORBER & UPPER CONTROL ARM
Removal
1) Disconnect actuator on vehicles with Variable Shock
Absorbers. On all models, raise and support vehicle. Support lower
control arm using jackstand. Remove front wheels. Remove lower shock
absorber bolt. Remove nut from top of shock absorber and remove shock
assembly from vehicle.
2) Remove the bump stop from the bump stop bracket. Mark
anchor arm bolt for reassembly reference. Loosen anchor arm bolt to
release torsion bar tension. Disconnect and plug brake hose at frame
mount bracket.
3) Remove cotter pin from upper ball joint stud. Loosen, but
DO NOT remove, ball joint stud nut. Using Steering Linkage Puller
(MB991406), loosen ball joint from steering knuckle. Remove brake hose\
clip and rebound stopper. Remove rebound stopper and brake hose
support from control arm.
4) Remove ABS sensor bracket (if equipped) and rebound
stoppers. Remove upper control arm mounting bolts and shim(s). Note
direction of bolt installation and locations of camber adjustment
shims. Remove control arm. Remove upper ball joint from control arm.
Inspection
Inspect control arm for cracks and deformation. Check ball
joints. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION.
Inspect ball joint dust cover for damage, and replace cover as
necessary.
Installation
1) To install, reverse removal procedure. Install control arm
bolts from outside of frame, with nuts against control arm. Install
the upper control with the marking "OUT" on shaft facing outside of
vehicle.
Page 1240 of 1501
2) Ensure alignment shims are placed in original locations.
Tighten shock absorber upper nut to end of threads, and install lock
nut. Tighten shock absorber upper nut until distance from end of
threads to nut is 0.04-0.08" (1.0-2.0 mm) on vehicles with standard
shock absorbers, and 0.06-0.10" (1.5-2.5 mm) on vehicles with Variable\
Shock Absorbers. Install lock nut.
3) Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Bleed brakes. Adjust anchor arm bolt to proper torsion bar setting.
See TORSION BAR under REMOVAL & INSTALLATION. Check wheel alignment,
and adjust it if necessary. See WHEEL ALIGNMENT SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT section.
WHEEL BEARING
Removal
Raise and support vehicle. Remove wheel assembly. Remove axle
hub. See AXLE HUB under REMOVAL & INSTALLATION. Clean any grease from
the inside surface of the front hub. Drive out the inner and outer
bearing races by tapping them uniformly using brass drift and hammer.
Installation
Lubricate bearing races. Install bearing races in hub using
Handle and Bearing Installer (MB990938 and MB990935). Ensure bearing
races are fully seated. To complete installation, reverse removal
procedure. Adjust wheel bearing preload. See WHEEL BEARING under
ADJUSTMENTS & INSPECTION .
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (MONTERO) \
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Application Ft. Lbs. (N.m)\
Anchor Arm Bolt Lock Nut ................................... 33 (44)\
Anchor Collar Vertical Bolt ................................ 33 (44)\
Ball Joint Nut
Lower .................................................. 108 (147)\
Upper .................................................... 54 (74)\
Bump Stop .................................................. 18 (25)\
Drive Flange ......................................... 36-43 (49-59)\
Ball Joint-To-Lower Control Arm Bolt ....................... 60 (81)\
Ball Joint-To-Upper Control Arm Bolt ....................... 19 (25)\
Caliper Bolt ............................................... 65 (88)\
Control Arm-To-Frame Bolt/Nut
Lower ................................................. 108 (147)\
Upper ................................................... 80 (108)\
Shock Absorber Shaft Nut .................................... 1 (15)\
Skid Plate ................................................. 17 (24)\
Stabilizer Bar Brackets .................................... 17 (24)\
Stabilizer Bar Lower Link .................................. 25 (33)\
Stabilizer Bar Upper Link .................................. 69 (93)\
Torque Arm Nut ............................................ 78 (106)\
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TORQUE SPECIFICATIONS (MONTERO SPORT) \
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Application Ft. Lbs. (N.m)\
Anchor Arm Adjusting Nut ................................... 32 (44)\
Anchor Arm Nut ............................................ 78 (106)\
Ball Joint Nut
Lower ........................................... 87-131 (118-177)\
Page 1244 of 1501
REAR SUSPENSION ASSEMBLY
NOTE: Procedures for Montero are for lateral rod, coil springs and
lower arms only. Procedures for Montero Sport are for leaf
springs only.
Removal (Montero)
1) Raise and support rear of vehicle. Place a jack under
center of rear axle housing. Remove parking brake cable attaching
bolts.
2) Remove rear speed sensor attaching bolt (if equipped).
Remove rear axle housing lock position harness attaching bolt and
lower shock bolts.
3) Remove lateral rod bolts and remove lateral rod. Remove
lower arm rear bolts. Remove lower arm front mounting nut and remove
lower arm. See Fig. 2.
Inspection
Check lateral rod for straightness and damage. Check rubber
bushings for deterioration, cracks and wear.
Installation
If lateral rod bushings need replacing, remove and install
using Lower Arm Bushing Arbor (MB990650). Apply a sufficient amount of\
liquid soap to bushings when installing them into lateral rod. If
lower arm rear bushings need replacing, remove and install rear
bushings using Rear Bushing Arbor (MB991293). To complete
installation, reverse removal procedure. Tighten all suspension
fasteners to specification with vehicle on ground and suspension
unloaded. See TORQUE SPECIFICATIONS .
Removal (Montero Sport)
1) Raise and support rear of vehicle. Place a jack under
center of rear axle housing.
2) Disconnect parking brake cable attaching bolts. Remove
rear speed sensor attaching bolt. Remove rear shock nuts and washers.
Remove rear shocks.
NOTE: The yellow shock mounts on left side and the pink one mounts
to the right side of vehicle.
3) Remove U-bolt nuts, U-bolt seat and U-bolts. Remove bump
stopper. Remove rear shackle plate nuts, shackle plate, bushings and
shackle assembly. Remove front shackle nuts and bolts. Remove leaf
spring. See Fig. 1.
Inspection
Check leaf springs for cracks and other damage. Inspect all
components and bushings for damage and wear. Replace components as
necessary.
Installation
To install, reverse removal procedure. Ensure shocks are
installed on proper side of vehicle. Tighten all suspension fasteners
to specification with vehicle on ground and suspension unloaded. See
TORQUE SPECIFICATIONS .
SHOCKS
Removal
1) Raise and support rear of vehicle. Place a jack under
center of rear axle housing. On Montero remove shock actuator (if
equipped).
Page 1245 of 1501
2) Remove upper shock mounting nuts and washers. On Montero
remove shock lower mounting nuts and bolts. On Montero Sport remove
shock lower mounting nuts and washers. Remove shock assembly.
Inspection
Check shock for oil leakage, abnormal noise and poor
function. Check coil spring for bending and weakness. Check rubber
parts for deterioration and cracks.
Installation
To install, reverse removal procedure. Tighten all fasteners
to specification. See TORQUE SPECIFICATIONS.
STABILIZER BAR
Removal
Raise and support vehicle. Support rear suspension assembly
using a jack. On Montero remove shock lower mounting bolts and nuts.
Remove stabilizer bar bracket and bushings. Remove stabilizer link
mounting nut and bolt. Remove stabilizer link joint cups, bushings and
collar. Remove stabilizer bar.
Inspection
1) Check bushings for wear and deterioration. Check
stabilizer bar, stabilizer link and all bolts for damage and wear.
Replace components as necessary.
Installation
To install, reverse removal procedure. When installing
stabilizer link, hold link using wrench and tighten nut until distance
from end of bolt to edge of nut is .59-.70" (15-17 mm). Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Upper Shock Nut
Montero .................................................. 11 (15)\
Montero Sport ............................................ 16 (22)\
Lower Shock Nut And Bolt
Montero ........................................ 159-181 (216-245)\
Montero Sport ............................................ 16 (22)\
Lateral Rod Nut And Bolt
Montero ................................................. 170 (230)\
Lower Arm Rear Nut And Bolt
Montero ................................................. 170 (230)\
Lower Arm Front Nut
Montero ................................................. 101 (137)\
Leaf Spring Rear Shackle Nut
Montero Sport ............................................. 38 (52)\
Leaf Spring Front Shackle Nut And Bolt
Montero Sport ........................................... 145 (196)\
"U" Bolt Nut
Montero Sport ...................................... 72-87 (98-118)\
Stabilizer Bar Bracket Bolt .......................... 25-26 (34-35)\
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Page 1354 of 1501
TRANSMISSION REMOVAL & INSTALLATION - A/T
1998 Mitsubishi Montero
1997-98 TRANSMISSION SERVICING
Mitsubishi Transmission Removal & Installation
Diamante, Eclipse, Galant, Mirage, Montero, 3000GT
REMOVAL & INSTALLATION
AWD & FWD MODELS
Removal
1) On all models except Galant, remove battery and battery
tray. On 3000GT, remove washer tank. On all models, remove air cleaner
cover with air inlet hose assembly. Raise and support vehicle. Remove
wheels. Remove undercover(s) (if equipped). Disconnect control cable\
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at transaxle. Drain transaxle fluid.
2) On AWD models, remove front exhaust pipe. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) Separate tie rod end. Separate lower ball joint. Separate
stabilizer bar connection (if necessary). Remove axle shafts. See
appropriate AXLE SHAFTS article in DRIVE AXLES. Remove center
crossmember assembly.
4) On AWD models, separate transfer assembly from transaxle.
Reference mark transfer assembly-to-drive shaft and remove transfer
assembly.
5) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
6) On all 4-cylinder models, support engine. On all models,
support transaxle with jack. Remove bolts from transaxle mounts.
Remove mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
Installation
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS .
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
RWD & 4WD MODELS
Removal
1) Disconnect negative battery cable. On Montero 4WD, remove
transfer case shift lever knob, dust boot and retainer plate or
console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
Page 1355 of 1501
and remove. Disconnect all external solenoid and switch connections.
3) On Montero 4WD, remove catalytic converter and front
exhaust pipe. On all models, disconnect speedometer cable and control
cables at transmission. Remove starter and bellhousing cover. Place
reference mark on torque converter and drive plate for reassembly
reference. Remove torque converter bolts. Push torque converter back
and away from drive plate.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
Installation
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS. Tighten mount bolts with
weight of engine and transmission on mounts. Ensure reference marks on
drive shaft(s) and torque converter-to-drive plate are matched.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS - FWD MODELS \
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Applications Ft. Lbs. (N.m)\
Ball Joint Nut ............................................ 74 (100)\
Center Crossmember Assembly Front Bolt ..................... 69 (93)\
Center Crossmember Assembly Rear Bolt ...................... 52 (70)\
Starter Bolts .............................................. 22 (30)\
Tie Rod End Nut ............................................ 21 (28)\
Torque Converter-To-Drive Plate Bolt ................. 33-38 (45-52)\
Transaxle-To-Engine Block Bolt
8-mm Bolt .................................................... ( 1)
10-mm Bolt ......................................... 22-25 (30-34)\
12-mm Bolt ......................................... 31-40 (42-54)\
Upper Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 54 (73)\
Lower Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 65 (88)\
( 1) - Tighten to 84-108 INCH lbs. (10-12 N.m).
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TORQUE SPECIFICATIONS - RWD MODELS \
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Applications Ft. Lbs. (N.m)\
Engine-To-Transmission Bolt ................................ 65 (88)\
Page 1358 of 1501
Lubricant level should be to bottom of fill hole on side of
transfer case.
RECOMMENDED FLUID
Transaxle/Transmission
Except Montero, use Diamond ATF SP-II. On Montero, use
Dexron-II ATF.
Transfer Cases
Use SAE 75W-85 gear oil with API GL-4 rating or higher.
FLUID CAPACITIES
TRANSAXLE/TRANSMISSION REFILL CAPACITIES \
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Application Qts. (L)\
Diamante ................................................. 9.0 (8.5)\
Eclipse
2.0L Non-Turbo ......................................... 9.1 (8.6)\
2.0L Turbo ............................................. 7.1 (6.7)\
2.4L ................................................... 6.4 (6.1)\
Galant ................................................... 6.3 (6.0)\
Mirage ................................................... 8.2 (7.8)\
Montero ................................................. 10.4 (9.8)\
3000GT ................................................... 7.9 (7.5)\
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TRANSFER CASE REFILL CAPACITIES \
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Application Pts. (L)\
Eclipse AWD ............................................... 1.0 (.5)\
Montero .................................................. 5.3 (2.5)\
Montero Sport ............................................ 4.9 (2.3)\
3000GT ..................................................... .6 (.3)\
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DRAINING & REFILLING
NOTE: Although manufacturer recommends changing only fluid, the
oil filter/screen may also require replacement. If replacing
oil filter/screen, note length and location of all bolts.
Transaxle (Except Montero)
1) Remove drain plug(s), and drain fluid. Some models may
contain a drain plug located in housing below axle shaft, in oil pan.
Remove oil pan. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS . Clean oil pan, replace
gasket, and install oil pan. Tighten oil pan bolts and drain plug to
specification. See TORQUE SPECIFICATIONS . Ensure dipstick hole area is
clean. Fill transmission with Diamond ATF SP-II, through filler tube,
until COLD level is reached on dipstick.
3) Start engine and allow to idle for 2 minutes. Shift
transaxle to each position, ending in Neutral. Add sufficient fluid to
reach lower mark. After reaching normal operating temperature, fluid
should be between upper and lower marks of HOT range on dipstick.
Transmission (Montero)
1) Remove drain plug (if equipped) from transmission pan, an\
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allow fluid to drain. On models without drain plug, oil pan must be
Page 1359 of 1501
removed to drain fluid. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS . Clean oil pan, replace
gasket, and install oil pan. Tighten oil pan bolts and drain plug to
specification. See TORQUE SPECIFICATIONS . Ensure dipstick hole area is
clean. Fill transmission with Dexron-II ATF, through filler tube,
until COLD level is reached on dipstick. Start engine, and allow to
idle for 2 minutes.
3) Shift transmission into each position, ending in Neutral.
Check fluid level with engine running at idle. If necessary, add
sufficient fluid to bring level to lower mark of dipstick. Recheck
fluid level after transmission is at normal operating temperature.
Transfer Case
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. Lubricant level should be
at bottom of fill hole on side of transfer case.
ADJUSTMENTS
KICKDOWN SERVO
Eclipse, Galant & 3000 GT
1) Remove all dirt and grease around kickdown servo switch.
Remove snap ring and kickdown servo switch.
2) To prevent servo piston from turning, install Adapter
(MD998915) and Kickdown Servo Wrench (MD998918) so tab of wrench
engages with notch of piston. See Fig. 1.
CAUTION: DO NOT push servo piston inward while installing adapter and
servo wrench. Install adapter in brake pressure port by hand
ONLY. DO NOT use wrench to tighten adapter.
Fig. 1: Adjusting Kickdown Servo (Eclipse, Galant & 3000 GT)
Courtesy of Mitsubishi Motor Sales of America.
3) Loosen lock nut to "V" channel of adjuster rod. Tighten
inner section of Kickdown Service Adjustment Assembly (MD998916) until\
Page 1360 of 1501
it contacts lock nut. See Fig. 1.
4) Install outer section of kickdown service adjustment
assembly on lock nut. Rotate outer section to left and inner section
to right to contact lock nut with inner section.
5) Using an INCH-lb. torque wrench on inner section, tighten
inner section to 89 INCH lbs. (10 N.m), and then loosen inner section.\
Tighten inner section to 44 INCH lbs. (5 N.m).
CAUTION: Before tightening lock nut with torque wrench, tighten it by
hand until it contacts piston. If torque wrench is used
initially, lock nut and adjustment rod may rotate together.
6) Back off outer section 2-2 1/4 turns. Rotate outer section
to right and inner section to left until inner section is free of lock
nut. Tighten lock nut by hand until it contacts piston. Using torque
wrench, tighten lock nut to 18-23 ft. lbs. (25-32 N.m).
7) Remove adapter and kickdown servo wrench. Install new "O"
ring in groove around switch. Install switch and snap ring.
SHIFT LINKAGE
Except Montero
1) Ensure shift and transaxle/transmission levers are both in
Neutral position. Loosen adjusting nut on control cable. See Fig. 2.
Loosen park/neutral position switch body bolts. Rotate park/neutral
position switch until hole in end of transmission manual control lever
is aligned with hole (cross section A-A) in flange of park/neutral
position switch body. Tighten park/neutral position switch body bolts.
Ensure holes in park/neutral position switch flange and transmission
manual control lever stay aligned.
2) Gently pull control cable from dust cover. Make sure shift
lever is still in Neutral. Tighten adjusting nut. Check
transaxle/transmission operation through all ranges. Readjust control
cable if necessary.
Fig. 2: Adjusting Shift Cable (Except Montero)
Courtesy of Mitsubishi Motor Sales of America.
Montero
Ensure shift and transmission levers are both in Neutral
Page 1367 of 1501
![MITSUBISHI MONTERO 1998 Manual Online ALTERNATOR article \
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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