MITSUBISHI MONTERO 2000 Service Repair Manual

22-1
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION 2..................
LUBRICANTS 2..............................
SEALANTS 2................................
SPECIAL TOOL 2............................
TROUBLESHOOTING 3.............
ON-VEHICLE SERVICE 6.....................
Transmission Oil Check 6.......................
Oil Replacement 6.............................4WD Detection Switch Continuity Check
7...................................
High/Low Detection Switch Continuity Check
7...................................
TRANSMISSION CONTROL 8.......
TRANSMISSION CONTROL 9.......
TRANSMISSION ASSEMBLY 10..............
4WD INDICATOR-ECU/TRANSFER-ECU 17....


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G
EN ER AL IN FO RM ATIO N
I te m s S
pecif ic a tio ns T
ra nsm is sio n model V
5M T1 V
5M 31 E
ngin e model 4
D 5 4
D 5 4
M 4 6
G 7 T
yp e 5
-s p eed, flo or-s h if t G
ear ra tio 1
st 3
.9 18 3
.9 52 4
.2 34 2
nd 2
.2 61 2
.2 38 3
rd 1
.3 95 1
.3 98 4
th 1
.0 00 5
th 0
.8 29 0
.8 19 0
.7 61 0
.8 19 R
eve rs e 3
.9 25 3
.5 53 T
ra nsfe r ty p e 2
-s p eed G
ear ra tio H
ig h 1
.0 00 L
ow 1
.9 25 1
.9 00 S
pecif ie d lu bric a nts Q
uantit y L T
ra nsm is sio n oil H
yp oid gearo il S AE 75W -9 0 or7 5W -8 5W co nfo rm in g to
A PIG L-4 3
.2 T
ra nsfe r oil H
yp oid gearo il S AE 75W -9 0 or7 5W -8 5W co nfo rm in g to
A PIG L-4 2
.5 S
pecif ie d se ala nt R
em ark s O
il fille r plu g 3
M AT D Part N o. 8660 or equiv a le nt S
em i- d ry in g se ala nt O
il d ra in plu g 3
M AT D Part N o. 8660 or equiv a le nt S
em i- d ry in g se ala nt N
um ber N
am e U
se M
D998464 T
e st harn ess
( 4 P, sq uare ) I
n sp ectio n of le ve r posit io n se nso r

MANUAL TRANSMISSION -Troubleshooting 22-3
TROUBLESHOOTING
For items other than the following service procedures, refer to GROUP 23 - Troubleshooting .
INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis
codeDiagnosis itemReference page
21Lever position sensor (LPS) system <4D5>Open circuit/Malfunc-
tion of sensor22-3
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No.21 Lever position sensor (LPS) system <4D5>Probable cause
If the LPS output voltage becomes 0.2 V or less at idling, code No.21 will be
set as opencircuit or maladjustment of the LPS.DMalfunction of the LPS
DMalfunction of harness or connector
DMalfunction of transfer-ECU
DMalfunction of the glow-ECU
NGOK
NG
Repair
MUT-II Data list
DNo.1 LPS
OK:Refer to P.23-5, DATA LIST
REFERENCE TABLE.
NG
ReplaceCheck the LPS.
(Refer to GROUP 17 - Emission
Control System)
OK
NG
Repair
OK
Check the following connector:
B-02
OK
OK
Check the following connector:D-114
Repair
NG
Repair
NG
Repair
OK
OK
Check the following connector:D-114
Measure at glow-ECU connector
D-114.
DECU terminal voltage
measurement
DIgnition switch: ON
DVoltage between terminal 7 and
earth
OK:4.8 - 5.2 V
NGNG
NGCheck the trouble symptoms.
OK
Measure at LPS connector B-02.
DDisconnect the connector and
measure at the harness side.
DVoltage between 2 and earth
(Ignition switch: ON)
OK:4.8 - 5.2 V
To the nextpage
Intermittent malfunction
(Refer to GROUP 00 - Points to
Note for Transient Malfunctions.)
OK
Check the harness wire between the
LPS and the glow-ECU, and repair if
necessary.
Check the harness wire between the
LPS and the glow-ECU, and repair if
necessary.
Replace the glow-ECU.


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MANUAL TRANSMISSION -Troubleshooting 22-4
OKOKOK
NG
NG
NG(1),(2) NG
Check the following connector:D-114
Repair OK
OK
OK
Measure at transfer-ECU connector
E-105.
DECU terminal voltage
measurement
DIgnition switch: ON
DVoltage between terminal 5 and
earth
OK:Acceleratorpedalfully
closed
800 - 1,000 mV
Acceleratorpedalfully de-
pressed
3,700 - 4,900 mV
Check the following connector:E-105
Check the trouble symptoms.OK
Check the following connectors:
E-105, E-113 NG
Replace the transfer-ECU. OK
NGRepairAdjust
Check the harness wire between the
LPS and the transfer-ECU, and
repair if necessary.
Check the harness wire between the
LPS and the transfer-ECU, and
repair if necessary.
From the previouspage
(3)NG
Measure at LPS connector B-02.
DUse the test harness
(MD998464) to connect connector
terminals No. 1, No. 2, No.3
only, and measure at the pick-up
harness.
DIgnition switch: ON
(1) Voltage between terminal 3 and
earth
OK:0.5 V or less
(2) Voltage between 2 and earth
(Ignition switch: ON)
OK:4.8 - 5.2 V
(3) Voltage between terminal 1 and
earth
OK:Acceleratorpedalfully re-
leased
800 - 1,000 mV
Acceleratorpedalfully de-
pressed
3,700 - 4,900 mV
NGAdjust the LPS.
(Refer to GROUP 17 - Emission
Control System)
Check the following connectors:
E-113, E-105
Repair
Check the harness wire between the
LPS and the glow-ECU, and repair if
necessary.


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MANUAL TRANSMISSION -Troubleshooting 22-5
DATA LIST REFERENCE TABLE
Data
list No.Check itemCheck conditionsNormal condition
1Lever positionEngine: StoppedAccelerator pedal: Fully closed800 - 1,000 mV
sensor (LPS)
<4D5>Selector lever position:
PAccelerator pedal: DepressedGradually increases from
the above value.
Accelerator pedal: Fully open3,700 - 4,900 mV
CHECK AT TRANSFER-ECU TERMINAL
Ter-
minal
No.Check itemCheck conditionsStandard value
5Lever position sensorAccelerator pedal: Fully closed (engine stopped)0.8 - 1.0 V
(LPS) <4D5>Accelerator pedal: Fully open (engine stopped)3.7 - 4.9 V


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O
N-V EH IC LE SER VIC E
T R ANSM IS SIO N OIL CHEC K
1 . Rem ove th e oil fille r plu g.
2 . Oil le ve l sh ould be at th e lo w er portio n of th e fille r plu g
h ole .
3 . Check th at th e tr a nsm is sio n oil is not notic e ably dir ty ,
a nd th at it has a su it a ble vis co sit y .
4 . Tig hte n th e fille r plu g to th e sp ecif ie d to rq ue.
T ig hte n in g to rq ue: 32 ±
2 N×
m
O IL REPLA CEM EN T
1 . Rem ove oil fille r plu g and oil dra in plu g.
2 . Dra in oil.
3 . Apply se ala nt to th e oil dra in plu g th re ads.
4 . Tig hte n th e oil dra in plu g to th e sp ecif ie d to rq ue.
T ig hte n in g to rq ue:
V 5M T1 39 ±
5 N×
m
V 5M 31 32 ±
2 N×
m
T ra n sfe r 32 ±
2 N×
m
S pecif ie d seala n t:
3 M ATD Part No. 8660 or eq uiv ale n t
5 . Fill w it h sp ecif ie d oil till th e le ve lc o m es to th e lo w erp ortio n
o f oil fille r plu g hole .
S pecif ie d tr a n sm is sio n oil:
H yp oid gear oil SA E 75W -9 0 or 75W -8 5W
c o nfo rm in g to API G L-4
Q uan tit y :
T ra n sm is sio n 3.2 L
T ra n sfe r 2.5 L
6 . Apply se ala nt to th e oil fille r plu g th re ads.
7 . Tig hte n th e oil fille r plu g to th e sp ecif ie d to rq ue.
T ig hte n in g to rq ue: 32 ±
2 N×
m
S pecif ie d seala n t:
3 M ATD Part No. 8660 or eq uiv ale n t F
ille r plu g hole O
il d ra in plu g O
il fille rp lu g O
il d ra in plu g T
ra n sfe r
< V 5M T1> O
il fille rp lu g O
il d ra in plu g O
il fille rp lu g O
il fille rp lu g O
il d ra in plu g

T
e rm in alN o. 1 2
2
H 4
H T
e rm in alN o. 1 2
4
H 4
L 4
H -4 L

T
R ANSM IS SIO N CO NTR O L
R EM OVA L AND IN STA LLA TIO N

T
R ANSM IS SIO N CO NTR O L
R EM OVA L AND IN STA LLA TIO N T
e rm in aln um ber t
io n 1 2 3 5 6
2
H 4
H 4
H Lc 4
LLc

T
R ANSM IS SIO N ASSEM BLY
R EM OVA L AND IN STA LLA TIO N
C au tio n
T he re ar pro pelle r sh aft is mad e of fib er-r e in fo rc ed pla stic tu be, so alw ays re fe r to GRO UP 25
p rio r to it s re m oval. <
4D 5 wit h V5M T1>
5
4 4
±1
0 N
×m
4
4
±1
0 N
×m
4 4
±1
0 N
×m
44
±1
0 N
×m
2
6
±4
N
×m 3
5
±6
N
×m
3
5
±6
N
×m
2 4
±5
N
×m
5
3
±5
N
×m
2
4
±5
N
×m
3 5
±6
N
×m
3 5
±6
N
×m 3
5
±6
N
×m
m 4
8
±6
N
×m
2 3
±3
N
×m
48
±6
N
×m
9 .0
±2
.0 N
×m 3
5
±6
N
×m
w
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P urc h ased f r o m w ww.W ork sh opM an uals .c o .u k