fluid MITSUBISHI MONTERO 1998 Manual Online

  Engine Coolant 
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 Automatic Transmission Fluid 
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 Rear Axle Oil 
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 Spark Plugs 
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 Timing Belt (
9) 
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 Ignition Cables (
8) 
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 Air Cleaner Filter 
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(
1) - Change once a year or every 7,500 miles (12,000 KM). 

(
2) - If mileage is less than 7,500 miles (12,000 KM) each year, 

replace the oil filter at every oil change. 

(
3) - Or inspect every 2 years. 

(
4) - Or inspect every year. 

(
5) - Or change every 2 years. 

(
6) - Or lubricate grease every 2 years. 

(
7) - Or inspect every 5 years. 

(
8) - Or replace every 5 years. 

(
9) - For California & Massachusettes, this maintenance is 

recommended but not required. 
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LUBRICATION SPECIFICATIONS 
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Material  Condition  Specification 
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Engine Oil  Ambient Temperature Less Than SAE 5W-30 

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1)  0F (-18C) To 100F (38C)  

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Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  
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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 
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Manual  All API Classification GL-4

Transmission   SAE 75W-85W Or 75W-90 
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Automatic  All  "ATF DEXRON II" Or 

Transmission   Equivalent 
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Brake Fluid  All  DOT 3 Or DOT 4 
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Rear Axle  All API Classification GL-5

  Or Higher (
2) 
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Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 
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(
1) - SAE 5W-30 engine oil is preferred. SAE 10W-30 may be used if 

the Ambient Temperature is above 0 F (-18 C). 

(
2) - SAE90, 85W-90, 80W-90 may be used in temperatures above 

-10 F (-23 C). SAE 80W, 80W-90 may be used in temperatures 

from -30 F (-34 C) to -10 F (-23 C). SAE 75W may be used 

in temperatures below -30 F (-34 C). 
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FLUID CAPACITIES 
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 Item  Condition  Specification (1) 
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Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

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 Oil Filter  0.32 Qts. (0.3L) 

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 Oil Cooler  0.32 Qts. (0.3L) 
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Engine  Drained; With Reserve Tank  10 Qts. (9.5L) 

Coolant   
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Automatic  Drained  8.9 Qts. (8.5L) 

Transmission   
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Manual  Drained  3.3 Qts. (3.2L) 

Transmission   
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Rear Axle  Drained  3.3 Qts. (3.2L) 
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Transfer Case Drained  2.6 Qts. (2.5L) 
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(
1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
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LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE
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Material  Condition  Specification 
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Engine Oil Ambient Temperature Less Than  SAE 5W-30 

(
1)  0F (-18C) To 100F (38C)  

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Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  
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Power  All Automatic Transmission 

Steering   Fluid DEXRON II 

Fluid   
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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 
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Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 
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Front Axle  All API Classification GL-5

  Or Higher (
2) 
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Clutch Fluid  All  DOT 3 Or DOT 4 
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Hook Lock  All  Multipurpose Grease 

Catch, Door   NLGI Grade 2 

Lock Strikers  

Seat Adjust-   

ers, Backdoor  

Lock, Parking  

Brake Cable   

Mechanism   
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 Front Wheel  All  Multipurpose Grease 

Bearings   NLGI Grade 2 Or 

  Equivalent 
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Door Hinges, All  Engine Oil 

Back Door   

Hinges   
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A/C  All  HFC-134a 

Refrigerant   
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Manual  All API Classification GL-4

Transmission   SAE 75W-85W Or 75W-90 
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Automatic  All  "ATF DEXRON II" Or 

Transmission   Equivalent 
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Brake Fluid  All  DOT 3 Or DOT 4 
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Rear Axle  All API Classification GL-5

  Or Higher (
2) 
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(
1) - SAE 5W-30 engine oil is preferred. SAE 10W-30 may be used if 

the Ambient Temperature is above 0 F (-18 C). 

(
2) - SAE90, 85W-90, 80W-90 may be used in temperatures above 

-10 F (-23 C). SAE 80W, 80W-90 may be used in temperatures 

from -30 F (-34 C) to -10 F (-23 C). SAE 75W may be used 

in temperatures below -30 F (-34 C). 
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FLUID CAPACITIES
FLUID CAPACITIES TABLE ( 1)
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Item  Condition  Specification 
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Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

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 Oil Filter  0.32 Qts. (0.3L) 

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 Oil Cooler  0.32 Qts. (0.3L) 
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Power  Drained  1.1 Qts. (1.0L) 

Steering   
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Automatic  Drained  8.9 Qts. (8.5L) 

Transmission   
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Manual  Drained  3.3 Qts. (3.2L) 

Transmission   
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Transfer Case Drained  2.6 Qts. (2.5L) 
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Front Axle  Drained  1.3 Qts. (1.2L) 
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Rear Axle  Drained  3.3 Qts. (3.2L) 
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A/C  Drained  27 oz (760 g) 

Refrigerant   
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Fuel Tank  Capacity  24 gal (92L) 

STEERING SYSTEM - POWER RECIRCULATING BALL
1998 Mitsubishi Montero
1997-98 STEERING
Mitsubishi - Power Recirculating Ball
Montero, Montero Sport
DESCRIPTION & OPERATION
STEERING GEAR
The power steering gear displaces fluid to provide hydraulic
pressure assist while turning. A one-piece rack piston nut is geared
to cross shaft. Backlash is adjusted with an adjusting screw.
STEERING LINKAGE
Linkage consists of an idler arm, relay rod, steering
knuckles and adjustable tie rods. Components are connected by ball
joints. Linkage assembly is connected to steering gear by pitman arm.
LUBRICATION
FLUID TYPE
Recommended fluid type is Dexron-II ATF.
FLUID LEVEL CHECK
Place vehicle in level position. Start engine and let idle.
Turn steering wheel left and right. Replace fluid if it has bubbles or
has become White. Fluid level should be between MIN and MAX marks on
dipstick. Fill to proper level.
FLUID REPLACEMENT
CAUTION: DO NOT crank engine for more than 15-20 seconds at a time.
1) Remove reservoir cap. Disconnect return hose at reservoir.
Drain fluid. Disconnect coil high tension wire. Raise and support
vehicle.
2) Turn steering wheel lock-to-lock several times while
cranking engine to drain fluid from steering gear. Reconnect hose.
Fill power steering system with fluid. Bleed system. See
HYDRAULIC SYSTEM BLEEDING .
HYDRAULIC SYSTEM BLEEDING
CAUTION: DO NOT crank engine for more than 15-20 seconds at a time.
Add fluid as needed during procedure to prevent reservoir
level from dropping.
1) Ensure reservoir is filled before bleeding. Add fluid (if
necessary) during bleeding. Raise and support front of vehicle.
Disconnect coil high tension wire.
2) While cranking engine, turn steering wheel lock-to-lock 5
or 6 times. Lower vehicle. Connect coil wire. Start engine and let
idle. Turn steering wheel lock-to-lock until no more bubbles appear in
oil reservoir.

3) Turn steering wheel lock-to-lock. Fluid level should not
change more than .2" (5 mm). If pump is noisy, fluid rises after
engine is turned off, or fluid level changes more than specified,
repeat bleeding procedure.
ADJUSTMENTS
BELT TENSION ADJUSTMENT SPECIFICATIONS
BELT ADJUSTMENT








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Application ( 1) Deflection: In. (mm)
Montero
New Belt ......................................... .42-.54 (11-14)\
Used Belt ........................................ .58-.66 (15-17)\
Montero Sport
2.4L
New Belt ......................................... .16-.24 (4-6)\
Used Belt ........................................ .24-.28 (6-7)\
3.0L
New Belt ....................................... .44-.52 (11-13)\
Used Belt ...................................... .56-.64 (14-16)\
( 1) - With 22 lbs. (10 kg) pressure applied midway on longest belt
run.









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STEERING WHEEL PLAY
Raise and support vehicle. Start engine and let idle. With
steering wheel in center position, ensure free play is 1.1" (27 mm) or\
less. If measured value exceeds specification, check steering gear
backlash and linkage ball joint end play. See STEERING GEAR BACKLASH
and LINKAGE BALL JOINT END PLAY.
STEERING GEAR BACKLASH
1) Set steering wheel in straight-ahead position. Raise and
support vehicle. Disconnect relay rod from pitman arm. Using a dial
indicator, measure steering gear backlash at top end of pitman arm.
2) Steering gear backlash should not exceed .02" (.5 mm). If\
measured value exceeds limit, turn steering gearbox adjusting bolt
until steering wheel free play is within specification. See Fig. 1.
Fig. 1: Measuring Steering Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.
TESTING

HYDRAULIC SYSTEM PRESSURE TEST
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), check
pressure. See POWER STEERING PUMP PRESSURE SPECIFICATIONS table.
Reinstall pressure hose. Do not twist hose or let hose interfere with
adjacent parts. Replace power steering pump 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.
POWER STEERING PUMP PRESSURE SPECIFICATIONS









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Application psi (kg/cm)
Valve Closed Or Wheel At Full Lock ............... 1204-1305 (83-90)\
Valve Open (Standard) ............................... 114-142 (8-10\
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Fig. 2: Connecting Pressure Gauge & Shutoff Valve
Courtesy of Mitsubishi Motor Sales of America.
P/S PRESSURE SWITCH

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-

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

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.

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.