service MITSUBISHI MONTERO 2000 Service Owners Manual

25-1
PROPELLER
SHAFT
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANT 2...............................SPECIAL TOOL 2............................
PROPELLER SHAFT 2.......................


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26-1
FRONT AXLE
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 4.................
LUBRICANTS 4..............................
SEALANTS 5................................
SPECIAL TOOLS 5..........................
ON-VEHICLE SERVICE 10...................
Wheel Bearing Backlash Check 10..............
Front Axle Total Backlash Check 10.............
Front Axle Gear Oil Level Check 11.............
Differential Carrier Oil Seal Replacement 11......
Solenoid Valve Operation Check 12..............
FRONT HUB AND KNUCKLE ASSEMBLY 13.
DRIVE SHAFT 16...........................
INNER SHAFT, HOUSING TUBE 24..........
FREEWHEEL CLUTCH ASSEMBLY,
DIFFERENTIAL CARRIER 28.................
FREEWHEEL CLUTCH ASSEMBLY 31.......
DIFFERENTIAL CARRIER 34.................
SOLENOID VALVE, VACUUMPIPE, VACUUM
TANK 49....................................
FRONT DIFFERENTIAL MOUNT 51..........


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FRONT AXLE -Service Specifications/Lubricants26-4
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Wheel bearing axis backlash mm-0
Front axle total backlash mm-11
Solenoid valve resistanceW36 - 46-
Hub rotation starting torque N×m-1.75
Setting of D.O.J. boot length mm80±5-
Opening dimension of the spe-
cial tool (MB991561) mmWhen the B.J. boot band
(small) is crimped.2.9-
When the B.J. boot band
(big) is crimped.3.2-
Crimped width of the B.J. boot band mm2.4 - 2.8-
Crimped height of B. J. boot band (big) mm-9.5
Final drive gear backlash mm0.11 - 0.16-
Drive gear runout mm-0.05
Differential gear backlash mm0 - 0.0760.2
Drive pinion turning torque N×mWithout oil seal0.83 - 1.19-
With oil sealCompanion flange (oil seal contact
surface) with anti-rust oil
0.93 - 1.128-
Companion flange (oil seal contact
surface) with gear oil
0.97 - 1.32-
LUBRICANTS
ItemsSpecified lubricantsQuantity
Front differential gear oilHypoid gear oil API classification GL-5 or higher, SAE
viscosity No. 90, 80W1.2 L
D.O.J. boot greaseRepair kit grease4M41-M/T:135±10 g
4M41-A/T, 6G7:
100±10 g
U.J.boot greaseRepair kit grease4M41-M/T:180±10 g
4M41-A/T, 6G7:
135±10 g


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27-1
REAR AXLE
CONTENTS
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS 3..............................
SEALANTS 4................................
SPECIAL TOOLS 5...........................
ON-VEHICLE SERVICE 8.....................
Rear Axle Total Backlash Check 8................
Gear Oil Level Check 8.........................
Wheel Bearing Axial Play Check 8................Rear Differential Lock Detection Switch Check 9....
Rear Differential Lock System Air Leakage
Check 9.......................................
REAR HUB ASSEMBLY 10...................
KNUCKLE 13...............................
DRIVE SHAFT 14............................
REAR DIFFERENTIAL LOCK 20..............
DIFFERENTIAL CARRIER 23.................


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31-1
WHEEL AND TYRE
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
TROUBLESHOOTING 3.......................ON-VEHICLE SERVICE 7.....................
Tyre Inflation Pressure Check 7.................
Tyre Wear Check 7............................
Wheel Runout Check 7.........................
WHEEL AND TYRE 7........................


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WHEEL AND TYRE -General Information/Service Specifications31-2
GENERAL INFORMATION
The wheels and tyres of the following specifications
have been established.
SPECIFICATIONS
Items4D5, 4M46G7
GL, GLXGLS
WheelTypeSteel type
Aluminium type*Aluminium typeAluminium type
Size16¢6JJ
16¢7JJ*16¢7JJ16¢7JJ
Amount of wheel offset mm464646
Pitch circle diameter (P.C.D.) mm139.7139.7139.7
TyreSize235/80R16 109S
265/70R16 112S*265/70R16 112S265/70R16 112H
NOTE
*: Optional items
SERVICE SPECIFICATIONS
ItemsLimit
Tread depth of tyre mm1.6
Wheel runout (Radial runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less
Wheel runout (Lateral runout) mmSteel wheel1.2 or less
Aluminium wheel1.0 or less


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Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.


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POWER PLANT MOUNT - No.1 Crossmember32-7
No.1 CROSSMEMBER
REMOVAL AND INSTALLATION
Caution
1. Before removing the steering wheel and airbag module assembly, always refer to GROUP 52B
- Service Precautions, Airbag Module and Clock Spring. Also, set the front wheels so that
they are facing straight forward, and remove the ignition key. If you fail to do this, the SRS
clock spring will be damaged, causing the SRS airbag to be inoperative and serious injury.
2. *: Indicates parts which should be initially tightened, and then fully tightened after placing
the vehicle horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal Operation
DUnder Cover Removal
DDrive Shaft Removal
(Refer to GROUP 26.)
DDifferential Carrier and No.2 Crossmember
Assembly Removal (Refer to GROUP 26 -
Freewheel Assembly and Differential Carrier.)
DUpper Arm Removal
(Refer to GROUP 33A.)
DLower Arm Removal
(Refer to GROUP 33A.)
DStabilizer Bar Removal
(Refer to GROUP 33A.)
DEngine Oil Cooler Removal<6G7>
(Refer to GROUP 12.)
DAir Cleaner Removal<4M4>
(Refer to GROUP 15.)
DIntercooler Removal<4M4>
(Refer to GROUP 15.)
DEngine Cover Removal
(Refer to GROUP 11A - Timing Belt.)
DRadiator Removal
(Refer to GROUP 14.)
DPower Steering Fluid Draining
(Refer to GROUP 37A - On - vehicle Service.)Post - installation Operations
DDifferential Carrier and No.2 Crossmember
Assembly Installation (Refer to GROUP 26 -
Freewheel Assembly and Differential Carrier.)
DDrive Shaft Installation
(Refer to GROUP 26.)
DLower Arm Installation
(Refer to GROUP 33A.)
DUpper Arm Installation
(Refer to GROUP 33A.)
DStabilizer Bar Installation
(Refer to GROUP 33A.)
DAir Cleaner Installation<4M4>
(Refer to GROUP 15.)
DIntercooler Installation<4M4>
(Refer to GROUP 15.)
DRadiator Installation
(Refer to GROUP 14.)
DEngine Oil Cooler Installation
(Refer to GROUP 12.)
DPower Steering Fluid Supplying
(Refer to GROUP 37A - On - vehicle Service.)
DPower Steering Fluid Line Bleeding
(Refer to GROUP 37A - On - vehicle Service.)
DPress the dust cover with a finger tocheck whether
the dust cover is cracked or damaged.
DChecking Steering Wheel Position with Wheels
StraightAhead
DFront Wheel AlignmentCheck and Adjustment
(Refer to GROUP 37A - On - vehicle Service.)
DUnder Cover Installation
DEngine Cover Installation
(Refer to GROUP 11A - Timing Belt.)


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33A-1
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION 1..................
SERVICE SPECIFICATIONS 3.................
SPECIAL TOOLS 3..........................
ON-VEHICLE SERVICE 4.....................
Wheel Alignment Check and Adjustment 4.......Ball Joint Dust Cover Check 6..................
UPPER ARM ASSEMBLY 7...................
SHOCK ABSORBER ASSEMBLY 10.........
LOWER ARM ASSEMBLY 13................
STABILIZER BAR 16........................


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FRONT SUSPENSION -On-vehicle Service33A-6
SIDE SLIP
Measure the side slip with a side slip tester.
Standard value: 0±
3mm
BALL JOINT DUST COVER CHECK
1. Check the dust cover for cracks or damage by pushing
it with finger.
2. If the dust cover is cracked or damaged, replace the
lower arm assembly or stabilizer link.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint.


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