1991 MITSUBISHI MONTERO 4WD

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Page 210 of 1333

MITSUBISHI MONTERO 1991 Service Manual Application In. (mm)
Montero .............................. .004-.020 (0.1-0.5)
Pickup & Ram-50 ..................... .028-.043 (0.7-1.09)
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Page 214 of 1333

$MITSUBISHI MONTERO 1991 Service Manual Removal 1) Raise and support vehicle. Remove front wheel(s). Separat\ e rubber flex hose from hydraulic line at brake hose mount, located on strut housing. Secure end of hydraulic li$

Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
e
rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic line to prevent spillage of
brake fluid.
2) Remove hose clip from brake hose mount. Disconnect brake
hose from caliper. Remove upper and lower caliper-to-steering knuckle
bolts. Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See the TORQUE SPECIFICATIONS table. Bleed brake
system. See BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal (Montero, Pickup 4WD & Ram-50 4WD)
Raise and support vehicle. Remove and support brake calipers.
Place hub in free-wheeling position. Remove drive hub cover using an
oil filter wrench and protective cloth. Remove snap ring, shim and
free-wheeling hub from drive axle. See Fig. 7. Remove lock washer.
Remove lock nut using Lock Nut Wrench (MB990954). Remove front hub
assembly.
Fig. 7: Exploded View of Front Brake Assembly (4WD)
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Install front hub assembly. Install and tighten lock nut
to 94-145 ft. lbs. (127-197 N.m), and then loosen and retighten to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Reverse removal
procedure for remaining components. After installation is complete,
check drive axle end play. Adjust end play if not .002" (.05 mm) or
less. Rotate drive axle forward and rearward until maximum end play is
obtained.
2) If adjusting axle shaft end play, use proper shim to
obtain desired end play. Shim is located behind snap ring on end of
drive axle. Install shim, and recheck axle end play.
Removal (Pickup 2WD & Ram-50 2WD)
Raise and support vehicle. Remove front caliper. Remove hub
(dust) cap, cotter pin and nut. Remove washer and outer wheel bearing.\
Remove front hub assembly. Remove bolts attaching rotor to front hub,
and separate assemblies.

Page 220 of 1333

$MITSUBISHI MONTERO 1991 Service Manual Fig. 13: Exploded View of Master Cylinder (Typical) Courtesy of Mitsubishi Motor Sales of America. DISC BRAKE SPECIFICATIONS DISC BRAKE SPECIFICATIONS TABLE��\ ��$

Page 221 of 1333

MITSUBISHI MONTERO 1991 Service Manual Maximum Refinish Diameter ..................... 10.1 (257)
Wheel Cylinder Diameter
Montero ................................... .875 (22.22)
Pickup & Ram-50
2WD ...........................

Page 224 of 1333

MITSUBISHI MONTERO 1991 Service Manual CO OLIN G S YSTE M S PEC IF IC ATIO NS

1991 M it s u bis h i M onte ro
1991 ENGINE COOLING
Mitsubishi Cooling System Specifications
Mitsubishi: Eclipse, Galant, Mira

Page 258 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \003 DRIV E A XLE - F R O NT 1991 M it s u bis h i M onte ro 1990-92 DRIVE AXLES Differentials & Axle Shafts - Front Montero, Pickup 4WD DESCRIPTION$

\003
DRIV E A XLE - F R O NT

1991 M it s u bis h i M onte ro
1990-92 DRIVE AXLES
Differentials & Axle Shafts - Front
Montero, Pickup 4WD
DESCRIPTION
Front axle assembly consists of differential carrier, housing
tube, inner shaft and drive axles. A full-floating axle design is
used. Drive axles are flexible assemblies made up of inner and outer
CV joints. Birfield Joints (BJ) and Double Offset Joints (DOJ) are
used at opposite ends of each drive axle.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS
\
\
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\

Application Ratio
Montero ............................ 4.63:1
Pickup ............................. 4.22:1
\
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NOTE: References to BJ refer to Birfield Joint and DOJ to Double
Offset Joint.
TESTING
TOTAL ASSEMBLY BACKLASH
Place transfer case in "4H" position. Raise and support
vehicle. Check total backlash at flange. If backlash at flange exceeds
.55" (14.0 mm), check assembly for wear and proper adjustment.
DRIVE AXLES R & I
REMOVAL
1) Remove undercover on Montero. Place hub in free-wheeling
position. Place transfer case in 2H position. Remove drive hub cover,
snap ring and shim from drive axle. Remove brake calipers and wire out
of way.
2) Using dial indicator, check drive axle end play. Rotate
drive axle forward and rearward until maximum end play is obtained.
End play must be adjusted during reassembly if not within .008-.020"
(.20-.50 mm). Disconnect tie rod assembly. Support lower control arm
with jack.
3) Separate ball joints from knuckle. Remove knuckle and
front hub assembly. Remove left drive axle from differential carrier.
Use care not to damage oil seal. On right drive axle, remove drive
axle-to-inner shaft retaining bolts. Remove right drive axle.
CAUTION: Support lower control arm during drive axle removal and
installation.

Page 268 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \003 DRIV E A XLE - R EA R N O N-IN TE G RAL 1991 M it s u bis h i M onte ro 1991�92 DRIVE AXLES Differentials & Axle Shafts - Rear Non-Integral Mitsubishi: Monter$

Page 284 of 1333

$MITSUBISHI MONTERO 1991 Service Manual runout. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS��\ ��\ ��\ ��\ ��\ ��\ ��\$

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