oil MITSUBISHI TRITON 1997 Service Manual

REAR AXLE ± Service Specifications27-4
SERVICE SPECIFICATIONS27100030121
ItemStandard valueLimit
Rear axle total backlash mm±5
Axle shaft axial play mmVehicles without ABS or rear differential lock0.05 ± 0.20±
Vehicles with ABS or rear differential lock0 ± 0.25±
Limited slip differential
p
reload Nm
Using special tool13 or more±
reload Nm
Without using special tool25 or more±
Axle shaft retainer
press-fitting force NVehicles without ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
78,000±
Vehicles with ABS or rear differential lockInitial press-fitting force
49,000 or more±
Final press-fitting force
98,000 ± 108,000±
Clearance between axle shaft retainer and snap ring mm0 ± 0.166±
Rear differential lock air pump pressure kPa25 ± 40±
Drive gear backlash mm2WD0.08 ± 0.13±
4WD0.13 ± 0.18±
Drive gear runout mm±0.05
Differential gear backlash mm2WD0 ± 0.250.2
4WD0 ± 0.0760.2
Limited slip differential
starting torque Nm
When a new clutch plate is used39 ± 74±
starting torque Nm
When re-installing current clutch plate25 ± 74±
Drive pinion
turning torque NmWithout oil sealWhen replacing
(with anti-rust agent)0.6 ± 0.9±
When replacing or reusing
(with gear oil applied)0.4 ± 0.5±
With oil sealWhen replacing
(with anti-rust agent)0.8 ± 1.1±
When replacing or
reusing (with gear oil applied)0.6 ± 0.7±

REAR AXLE ± Service Specifications/Lubricants/Sealants27-5
ItemStandard valueLimit
Horizontal difference between friction plate and friction disc thickness mm0 ± 0.05±
Clearance between friction plate and friction disc mm0.06 ± 0.20±
Clearance in side gear axial direction mm0.05 ± 0.20±
Difference between left and right dimensions from back thrust face of pressure
ring to end of thrust washer mm0 ± 0.05±
Friction plate and friction disc warping (flatness) mm±0.08
Friction plate and friction disc wear
(difference in the thickness of the friction surface and the projections) mm±0.1
LUBRICANTS27100040049
ItemSpecified lubricantsQuantity
Rear differential gear oil
Conventional differential:
Hypoid gear oil
API classification GL-5 or higher SAE viscosity No. 90,
80 W

Limited slipdifferential:
2WD1.6


Limited sli differential:
Hypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 8149630 EX
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL-5, SAE 80W-90) or equivalent4WD2.6

SEALANTS27100050042
ItemsSpecified sealantsRemarks
Bearing case3M ATD Part No. 8661 or equivalentSemi-drying sealant
Dust cover
Axle housing (differential carrier mounting part)
Drive gear and differential case mounting part3M Stud Locking 4170 or equivalentAnaerobic sealant

G
EN ER AL IN FO RM ATIO N 33200010105
T he fr o nt s u sp ensio n o n 2 W D v e hic le s is a n
i n dependent s u sp ensio n s yste m h avin g th e d ouble
w is h bone c o m bin ed w it h th e c o il s p rin g, w hile th e f
r o nt s u sp ensio n o n 4 W D v e hic le s is a n
i n dependent s u sp ensio n h avin g th e d ouble
w is h bone c o m bin ed w it h th e to rs io n b ar s p rin g.
C O IL S PR IN G < 2W D>
I te m s 4
G 63-S in gle c a b,
4 D 56-C lu b c a b 4
G 63-D ouble c a b,
4 D 56-S in gle c a b 4
D 56-D ouble c a b W
ir e d ia . x O .D . x
f r e e le ngth m m 1
6 y 99 y 2 80
[ 1 7 y 1 00 y 2 75] 1
6 y 100 y 2 84
[ 1 7 y 1 00 y 2 79] 1
6 y 100 y 2 88
[ 1 7 y 1 00 y 2 83] S
pecif ic a tio n L
ength x O .D . m m 1
,3 67 y 2 6 [1 ,3 67 y 2 7] K
nuckle S
tr u t b ar S
hock a bso rb er T
o rs io n b ar K
nuckle L
ow er a rm S
ta biliz e r b ar S
hock a bso rb er C
oil s p rin g L
ow er a rm

BASIC BRAKE SYSTEM ± Troubleshooting35A-7
TROUBLESHOOTING35100070081
SymptomProbable causeRemedy
Vehicle pulls to one side
when brakes are applied
Grease or oil on pad or lining surfaceReplace
when brakes are a lied
Inadequate contact of pad or liningCorrect
Auto adjuster malfunctionAdjust
Drum eccentricity or uneven wearRepair or replace as necessary
Insufficient braking powerLow or deteriorated brake fluidRefill or change
Air in brake systemBleed air
Overheated brake rotor due to dragging of pad
or liningCorrect
Inadequate contact of pad or lining
Brake booster malfunction
Clogged brake line
Grease or oil on pad or lining surfaceReplace
Load sensing proportioning valve malfunction
Auto adjuster malfunctionAdjust
Increased pedal stroke
(Reducedpedal to floor
Air in brake systemBleed air
(Reduced edal to floor
board clearance)Worn lining or padReplace
Broken vacuum hose
Faulty master cylinder
Brake fluid leaksCorrect
Auto adjuster malfunctionAdjust
Excessive push rod to master cylinder
clearance
Brake dragIncomplete release of parking brakeCorrect
Clogged master cylinder return port
Incorrect parking brake adjustmentAdjust
Improper push rod to master cylinder
clearance
Faulty master cylinder piston return springReplace
Worn brake pedal return spring
Broken rear drum brake shoe to shoe spring
Lack of lubrication in sliding partsLubricate

BASIC BRAKE SYSTEM ± Troubleshooting35A-8
SymptomProbable causeRemedy
Insufficient parking brake functionWorn brake lining or padReplace
Grease or oil on lining or pad surface
Parking brake cable sticking
Stuck wheel cylinder or caliper piston
Excessive parking brake lever strokeAdjust the parking brake lever stroke or
check the parking brake cable routing
Auto adjuster malfunctionAdjust
Scraping or grinding noise when
brakes are applied
Worn brake lining or padReplace
brakes are a lied
Caliper to wheel interferenceCorrect or replace
Dust cover to disc interference
Bent brake backing plate
Cracked drums or brake disc
Squealing, groaning or chattering
noise when brakes are appliedDisc brakes ± Missing or damaged
brake pad anti-squeak shimReplace
Brake drums and linings, discs and pads
worn or scoredCorrect or replace
Improper lining parts
Disc brake ± Burred or rusted calipersCorrect or deburr
Dirty, greased, contaminated or glazed
liningsClean or replace
Drum brakes ± Weak, damaged or
incorrect shoe hold-down springs, loose
or damaged shoe hold-down pins and
springsCorrect or replace
Incorrect brake pedal or booster push rodAdjust

ABS <2WD> ± Troubleshooting35B-10
Code No. 41, 42, 43 Solenoid valveProbable cause
The ABS-ECU always monitors the solenoid valve drive circuit. It determines that
there is an open or short-circuit in the solenoid coil or in a harness: When no current
flows in the solenoid even though the ABS-ECU turns on it, and vice versa.
Malfunction of wiring harness

Malfunction of hydraulic unit

Malfunction of ABS-ECU
NG
Check the harness between the hydrau-
lic unit and ABS-ECU, and repair if nec-
essary.
OK
Check trouble symptoms.
Measure at hydraulic unit connector
A-09.

Disconnect the connector and
measure at the harness side.

Resistance values between the
following terminals
1-5, 2-5, 3-5
OK: 5.0 W
6-5, 7-5, 8-5
OK: 2.2 WNGReplace the hydraulic unit.
OK
Measure at hydraulic unit connector
A-09 and ABS-ECU connectors C-62
and C-64.

Disconnect the connector and
measure at the harness side.

Continuity between the following
terminals
OK:Continuity
HU side
ABS-ECU
side (C-64)
HU side
ABS-ECU
side (C-62)NGCheck the following connectors.
A-09, C-62 and C-64NG
Repair
OK
Measure at hydraulic unit connector
A-09 and valve relay connector A-39.

Disconnect the connector and
measure at the harness side.

Continuity between the following
terminals
OK:Continuity
HU side
Valve relay sideNGCheck the following connector and
diode.
A-09 and A-39NG
Repair
OK
Check trouble symptoms.NGCheck the harness between the hydrau-
lic unit and valve relay, and repair if nec-
essary.
OK
Check the following connectors.
C-62 and C-64NG
Repair
OK
Check trouble symptoms.NGReplace the ABS-ECU. 1
52
2
14 6
41
3
37
18
2
5
310
3

STEERING ± Service Specifications37A-3
SERVICE SPECIFICATIONS37100030021
ItemsStandard valueLimit
Steering wheel free play mmWith engine running±50
With engine stopped10 or less±
Steering angle2WDInner wheel33
55' ± 36
55'±
Outer wheel30
57'±
4WDInner wheel29
40' ± 32
40'±
Outer wheel29
30'
Steering gear backlash mm±0.5
Variation of tie rod end ball joint shaft direction mm±1.5
Tie rod end ball joint starting torque Nm3.0±
Steering gear oil level mm22±
Engine idle speed r/min4G6750 + 100±
4D56750 + 100±
Stationary steering effort N39.2 or less±
Oil pump
p
ressure MPa
Oil pump relief pressure8.3 ± 9.0±
ressure MPa
Pressure under no-load conditions0.8 ± 1.0±
Steering gear retention hydraulic pressure8.3 ± 9.0±
Oil pressure switch operating pressure MPaOFF
ON1.5 ± 2.0±
ON
OFF0.7 ± 1.2±
Mainshaft starting torque Nm0.49 ± 0.78±
Cross-shaft axial play mm0.05 or less±
Mainshaft total starting torque Nm<2WD>0.98 ± 1.47±
<4WD>0.69 ± 1.28±
Pitman arm ball joint starting torque Nm0.5 ± 1.5±
Mainshaft axial play mm0.03 or less±
Backlash between ball groove of rack piston and balls mm±0.05
Idler arm sliding resistance N2WD8.8 ± 30±
4WD2.4 ± 16±

(
C onta ctin g s u rfa ce ) <
2W D> <
4W D> 9
5 N m
7
7I
d le r A rm
Id le r a rm d is assem bly s te p s
1 . S elf - lo ckin g n ut
2 . W ash er
3 . Id le r a rm a sse m bly

C 4. B ush in g

B 5. O il s e al
6 . Id le r a rm
7 . Id le r a rm s u pport T
ie r o d d is assem bly s te p s

A 8. Tie r o d e nd a sse m bly
9 . P ip e
R EA SSEM BLY S ER VIC E P O IN TS

A TIE -R O D E N D IN STA LLA TIO N
1 . Apply m ult ip urp ose g re ase to th e th re aded s e ctio n o f
t h e tie -ro d e nd.
2 . Scre w in th e r ig ht a nd le ft tie -ro d e nds to th e p ip e b y
t h e s a m e a m ount, a nd th en a nd p ro vis io nally tig hte n th e
t ie -ro d e nd fix in g n ut.

B OIL S EA L IN STA LLA TIO N M
B990926 M
B990938

SRS ± SRS Diagnosis Unit (SDU)/Air Bag Module and Clock Spring52B-28
INSPECTION52400220093

Check the SDU and brackets for dents, cracks or
deformation.

Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust is discovered,
replace the SDU with a new one.
NOTE
For checking of the SDU other than described above,
refer to the section concerning troubleshooting. (Refer
to P.52B-6.)
AIR BAG MODULE AND CLOCK SPRING52400240143
Caution
1. Disconnect the battery (±) terminal and wait
for 60 seconds or more before starting work.
Furthermore, the disconnected battery
terminal should be covered with tape to
insulate it. (Refer to P.52B-3, No.4.)
2. Never attempt to disassemble or repair the
air bag modules or clock spring.
If faulty, replace it.
3. Do not drop the air bag modules or clock
spring or allow contact with water, grease
or oil.
Replace it if a dent, crack, deformation or
rust is detected.4. The air bag modules should be stored on
a flat surface and placed so that the pad
surface is facing upward.
Do not place anything on top of it.
5. Do not expose the air bag modules to
temperatures over 93C.
6. After deployment of an air bag, replace the
clock spring with a new one.
7. Wear gloves and safety glasses when
handling air bags that have already
deployed.
8. An undeployed air bag module should only
be disposed of in accordance with the
procedures (Refer to P.52B-34.)

± General Information HEATER, AIR CONDITIONER
AND VENTILATION55-3
GENERAL INFORMATION55200010121
The heater system uses a two-way-flow full-air-mix
system that features high performance and low
operating noise, and includes an independent face
air blowing function and a cool air bypass function.The A/C system is basically the same as the
conventional system, but a new refrigerant system
has been adopted as a response to restrictions
on the use of chlorofluorocarbons.
ItemsSpecifications
Heater unitTypeTwo-way-flow full-air-mix system
Heater control assemblyDial type
CompressorModelInclined-plate type
Dual pressure switch
kPa
High-pressure switchON
OFF: 2,648, OF
F ON: 2,059
kPa
Low-pressure switchON
OFF: 177, OFF
ON: 186
Refrigerant and quantity gR-134a (HFC-134a), Approx. 550 ± 600
SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon
(HFC) which contains hydrogen atoms in place of
chlorine atoms, it will not cause damage to the
ozone layer.
Refrigerant R-134a is transparent and colourless
in both the liquid and vapour state. Since it has
a boiling point of ± 29.8
C, at atmospheric pressure,
it will be a vapour at all normal temperatures and
pressures. The vapour is heavier than air,
non-flammable, and nonexplosive. The following
precautions must be observed when handling
R-134a.Caution
Wear safety goggles when servicing the
refrigeration system.
R-134a evaporates so rapidly at normal
atmospheric pressures and temperatures that it
tends to freeze anything it contacts. For this reason,
extreme care must be taken to prevent any liquid
refrigerant from contacting the skin and especially
the eyes. Always wear safety goggles when
servicing the refrigeration part of the A/C system.
Keep a bottle of sterile mineral oil handy when
working on the refrigeration system. Should any
liquid refrigerant get into the eyes, use a few drops
of mineral oil to wash them out. R-134a is rapidly
absorbed by the oil. Next splash the eyes with
plenty of cold water. Call your doctor immediately
even though irritation has ceased after treatment.