bolt pattern MITSUBISHI MONTERO 1998 Service Manual

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

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert a clutch alignment tool to prevent
pressure plate and clutch disc from dropping. Loosen pressure plate
bolts gradually in a crisscross pattern to avoid warping pressure
plate flange during removal. Remove pressure plate and clutch disc.
See Fig. 3 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

DO NOT clean release bearing assembly in solvent. Inspect hydraulic
system components for fluid leakage. Inspect cylinder dust boot for
cracks or deterioration.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure depth from
clutch disc surface to head of rivet. Replace clutch disc if
measurement is less than .012" (.30 mm). See Fig. 4. Replace worn or
defective components as necessary.
Fig. 4: Measuring Clutch Disc (Typical)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS .
2) Clean release bearing sliding surface. Apply a light
coating of multipurpose grease to release bearing sliding surface.

spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion companion flange, washer and
retaining nut. Tighten nut to 137 ft. lbs. (190 N.m).
2) Using INCH-lb. torque wrench, check pinion rotating torque
without pinion oil seal. See PINION ROTATING TORQUE SPECIFICATIONS
table. Adjust rotating torque by replacing drive pinion front shims or
spacer. Once correct rotating torque is obtained, install oil seal.
Coat seal lip with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install NEW
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
Side Bearing Installation
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal in thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier housing.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges (feeler gauges 180 degrees opposed), measure clearance
between carrier and side bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add .002" (.05 mm) to\
50% of measured clearance and then add thickness measurement of
removed shim. This is thickness of new shim that should be installed
on each side of case. Install equal thickness shims on each side of
case assembly.
NOTE: Ensure zero clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Check ring gear backlash.
Ring Gear Backlash
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash should be .004-.006" (.10-.15 mm).
2) If backlash is not within specification, change side
bearing adjusting shims and recheck backlash. See
GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Check gear
tooth contact using Prussian Blue.
CAUTION: When changing shims, total thickness of all shims must
remain constant to ensure correct bearing preload.
Ring Gear Runout
Using dial indicator, measure runout at back side of ring
gear. Runout should not exceed .002" (.05 mm). If runout is excessive,\
change ring gear-to-differential case mounting position. Ensure ring
gear mounting bolts are tightened to correct specification. Recheck
runout. Install cover and gasket.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\

as matched set. Side gears and pinion gears must be replaced as
matched set.
Reassembly & Adjustment
1) Install thrust spacers, side gears, pinion washers and
pinion gears in differential case. DO NOT install thrust block (if
equipped) at this time.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. See
Fig. 8 . Using dial indicator, measure gear backlash. Backlash should
be .0004-.0030" (.010-.080 mm). Service limit is .008" (.20 mm).
3) Adjust backlash by using different side gear spacers.
Ensure both sides are equally shimmed. Install thrust block (if
equipped) once correct backlash is obtained. Install pinion shaft lock
pin from ring gear side of carrier housing. Securely stake pin in 2
places. Ensure adhesive is removed from ring gear mounting bolts and
gear mounting surface. Clean internal threads with tap.
4) Ensure alignment marks on differential case and ring gear
align. Apply Loctite 271 to bolts, and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS . Using appropriate adapter,
press on carrier side bearings.
DIFFERENTIAL ASSEMBLY (LIMITED SLIP)
NOTE: Manufacturer does not provide disassembly or reassembly
procedures for locking type differential. Use illustrations
for exploded views of assembly. See Figs. 11 and 12.
NOTE: See PRE-DISASSEMBLY INSPECTION under
DIFFERENTIAL ASSEMBLY (CONVENTIONAL) before disassembling
carrier assembly. For carrier assembly and drive pinion
removal, see DIFFERENTIAL ASSEMBLY (CONVENTIONAL) .
Disassembly
1) Once ring gear is removed, loosen carrier housing screws
in diagonal pattern. Separate cases and remove components. See Fig. 10
. Maintain parts in order of disassembly. Clean all parts in new
solvent.
2) Inspect condition of friction and spring plates and
friction discs. Replace disc and/or plates if worn or heat damaged.
Distortion of discs will cause incorrect clutch pressure. Scratches,
nicks or burrs on components can be repaired with an oil stone.
3) Discs must be flat and free of distortion. Check discs on
surface plate with dial indicator. Maximum warpage of friction plate
or disc is .003" (.08 mm). Inspect thickness of discs and plates.
Thickness limit between discs and plates is .004" (.10 mm).
Fig. 10: Exploded View Of Limited Slip Differential
Courtesy of Mitsubishi Motor Sales of America.

PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS









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Application INCH Lbs. (N.m)\
Oil Seal Not Installed
With Lubrication ................................. 3.5-4.3 (.4-.5)\
Without Lubrication .............................. 5.2-7.8 (.6-.9)\
Oil Seal Installed
With Lubrication ............................... 5.6-6.5 (.65-.75)\
Without Lubrication .......................... 7.4-10.0 (.85-1.15)\









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3) Install cylinder gauge in side bearing seats. Ensure flat
areas align, and gauge contacts side bearing seat firmly. Select
adjusting shim with same thickness as gap between cylinder gauge and
pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected
adjusting shims between drive pinion gear and rear pinion bearing.
Using bearing installer and press, install rear pinion bearing.
5) Install drive pinion in differential housing. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal. Install pinion companion flange, washer and retaining nut.
Tighten nut to specification. See TORQUE SPECIFICATIONS.
6) Check pinion rotating torque. See
PINION ROTATING TORQUE SPECIFICATIONS table. Adjust rotating torque by
replacing drive pinion front shims or spacer. Once correct rotating
torque is obtained, install oil seal. Coat seal lip with grease.
Install pinion companion flange so alignment marks are correct. Apply
light coat of grease to contact area of pinion flange washer.
7) Install NEW retaining nut. Recheck pinion rotating torque.
Ensure rotating torque is within specification. Press side bearings
onto differential case. Install outer races. Install differential
carrier into differential housing. Align bearing cap index marks, and
snug carrier cap bolts. Ensure outer races and bearing caps are
installed in original location.
8) Install side bearing nuts. Tighten bearing cap bolts to
specification. See TORQUE SPECIFICATIONS . Tighten bearing nuts until
bearing outer races are seated against bearings. Adjust ring gear
backlash.
Ring Gear Backlash
1) Secure drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. See Fig. 6. Measure at
4 locations of ring gear. Gear backlash must be within specification.
Backlash should be .005-.007" (.13-.18 mm).
2) If backlash is less than specification, loosen side
bearing nut at back of ring gear, and tighten side bearing nut on
tooth side of ring gear by same amount. If backlash exceeds
specification, loosen side bearing nut at tooth side of ring gear, and
tighten side bearing nut at back of ring gear by same amount.
3) After adjusting backlash, tighten both side bearing nuts
half the distance between 2 adjacent holes on side bearing nut.
Recheck backlash. Ensure bearing cap bolts are tightened to
specification. See TORQUE SPECIFICATIONS .
4) Lock plates are of 2 designs for hole location of side
bearing nuts. Install proper type lock plate. Tighten lock plate bolt
to specification. See TORQUE SPECIFICATIONS. Check gear tooth contact
pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL
INFORMATION.
Ring Gear Runout

CYLINDER BLOCK
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
BLOCK CLEANING
Only cast cylinder blocks should be hot tank cleaned.
Aluminum cylinder blocks should be cleaned using cold tank method.
Cylinder block is cleaned in order to remove carbon deposits, gasket
residue and water jacket scale. Remove oil galley plugs, freeze plugs
and cam bearings prior to block cleaning.
BLOCK INSPECTION
Visually inspect the block. Check suspected areas for cracks
using the Dye Penetrant inspection method. Block may be checked for
cracks using the Magnaflux method.
Cracks are most commonly found at the bottom of the
cylinders, the main bearing saddles, near expansion plugs and between
the cylinders and water jackets. Inspect lifter bores for damage.
Inspect all head bolt holes for damaged threads. Threads should be
cleaned using tap to ensure proper head bolt torque. Consult machine
shop concerning possible welding and machining (if required).
CYLINDER BORE INSPECTION
Inspect the bore for scuffing or roughness. Cylinder bore
is dimensionally checked for out-of-round and taper using dial bore
gauge. For determining out-of-round, measure cylinder parallel and
perpendicular to the block centerline. Difference in the 2 readings
is the bore out-of-round. Cylinder bore must be checked at top, middle
and bottom of piston travel area.
Bore taper is obtained by measuring bore at the top and
bottom. If wear has exceeded allowable limits, block must be honed
or bored to next available oversize piston dimension.
CYLINDER HONING
Cylinder must be properly honed to allow new piston rings to
properly seat. Cross-hatching at correct angle and depth is critical
to lubrication of cylinder walls and pistons.
A flexible drive hone and power drill are commonly used.
Drive hone must be lubricated during operation. Mix equal parts of
kerosene and SAE 20w engine oil for lubrication.
Apply lubrication to cylinder wall. Operate cylinder hone
from top to bottom of cylinder using even strokes to produce 45 degree
cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone
to extend below cylinder during operation.
Recheck bore dimension after final honing. Wash cylinder
wall with hot soapy water to remove abrasive particles. Blow dry with
compressed air. Coat cleaned cylinder walls with lubricating oil.
DECK WARPAGE
Check deck for damage or warped head sealing surface. Place
a straightedge across gasket surface of the deck. Using feeler gauge,
measure clearance at center of straightedge. Measure across width and

In certain conditions, the pitch of the exhaust gases may
sound like gear whine. At other times, it may be mistaken for a wheel
bearing rumble.
Tires, especially radial and snow, can have a high-pitched
tread whine or roar, similar to gear noise. Also, some non-standard
tires with an unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or
excessive driveline play that can be improperly diagnosed as drive
axle problems.
Trim and moldings also can cause a whistling or whining
noise. Ensure none of these components are causing the noise before
disassembling the drive axle.
Gear Noise
A "howling" or "whining" noise from the ring and pinion gear
can be caused by an improper gear pattern, gear damage, or improper
bearing preload. It can occur at various speeds and driving
conditions, or it can be continuous.
Before disassembling axle to diagnose and correct gear
noise, make sure that tires, exhaust, and vehicle trim have been
checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick
against the spokes of a spinning bicycle wheel. It occurs while
decelerating from 40 MPH and usually can be heard until vehicle comes
to a complete stop. The frequency varies with the speed of the
vehicle.
A chuckle that occurs on the driving phase is usually caused
by excessive clearance due to differential gear wear, or by a damaged
tooth on the coast side of the pinion or ring gear. Even a very small
tooth nick or a ridge on the edge of a gear tooth is enough the cause
the noise.
This condition can be corrected simply by cleaning the gear
tooth nick or ridge with a small grinding wheel. If either gear is
damaged or scored badly, the gear set must be replaced. If metal has
broken loose, the carrier and housing must be cleaned to remove
particles that could cause damage.
Knock
This is very similar to a chuckle, though it may be louder,
and occur on acceleration or deceleration. Knock can be caused by a
gear tooth that is damaged on the drive side of the ring and pinion
gears. Ring gear bolts that are hitting the carrier casting can cause
knock. Knock can also be due to excessive end play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic
transmission is engaged in Reverse or Drive, or when throttle is
applied or released. It is caused by backlash somewhere in the
driveline, but not necessarily in the axle. To determine whether
driveline clunk is caused by the axle, check the total axle backlash
as follows:
1) Raise vehicle on a frame or twinpost hoist so that drive
wheels are free. Clamp a bar between axle companion flange and a part
of the frame or body so that flange cannot move.
2) On conventional drive axles, lock the left wheel to keep
it from turning. On all models, turn the right wheel slowly until it
is felt to be in Drive condition. Hold a chalk marker on side of tire
about 12" from center of wheel. Turn wheel in the opposite direction
until it is again felt to be in Drive condition.
3) Measure the length of the chalk mark, which is the total