1991 MITSUBISHI MONTERO clutch
[x] Cancel search: clutchPage 715 of 1333
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
\
\
\
\
\
\
\
Fluid Capacities
\
\
\
\
\
\
\
Application Quantity
Engine Oil
1987 ......................................... 5.2 Qts. (5.0L)
1988 ......................................... 5.0 Qts. (4.8L)
1989-92 ...................................... 5.5 Qts. (5.3L)
1993-95 ...................................... 5.2 Qts. (4.9L)
\
\
\
\
\
\
\
\f
75,000 MILE (120,000 KM) SERVICE
75,000 MILE (120,000 KM) SERVICE \
\
\
\
\
\
\
Service Or Inspect
\
\
\
\
\
\
\
Verify Last Major Service Was Performed
\b\
\
\
\
\
\
\
Fluid Levels
\b\
\
\
\
\
\
\
Braking System
\b\
\
\
\
\
\
\
Drive Shaft Boots
\
\
\
\
\
\
\
Replace
\
\
\
\
\
\
\
Engine Oil
\b\
\
\
\
\
\
\
Oil Filter
\
\
\
\
\
\
\
Lubrication Specifications
\
\
\
\
\
\
\
Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ........... SAE 90, 85W-90, 80W-90
API GL-5
Maximum Temperature
Less Than -30
F (-34
C) .................... SAE 75W API GL-5
Power Steering Fluid ............................. Dexron-II ATF
Rear Axle (With Limited
Slip Differential) ............ Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic ...................................... Dexron-II ATF
Manual Transaxle &
Transfer Case (4WD) ................. SAE 75W-85W, 75W-90 API
Page 718 of 1333
![MITSUBISHI MONTERO 1991 Service Manual Replace
\
\
\
\
\
\](/manual-img/19/57332/w960_57332-717.png "MITSUBISHI MONTERO 1991 Service Manual Replace
\
\
\
\
\
\")
Replace
\
\
\
\
\
\
\
Air Filter
\b\
\
\
\
\
\
\
Spark Plugs
\b\
\
\
\
\
\
\
Drive Axle Fluid (With Limited-Slip Differential)
\b\
\
\
\
\
\
\
Automatic Transmission & Transfer Case Fluids
\b\
\
\
\
\
\
\
Engine Oil & Filter
\b\
\
\
\
\
\
\
Engine Coolant
\
\
\
\
\
\
\
Lubrication Specifications
\
\
\
\
\
\
\
Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ........... SAE 90, 85W-90, 80W-90
API GL-5
Maximum Temperature
Less Than -30
F (-34
C) .................... SAE 75W API GL-5
Power Steering Fluid ............................. Dexron-II ATF
Rear Axle (With Limited
Slip Differential) ............ Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic ...................................... Dexron-II ATF
Manual Transaxle &
Transfer Case (4WD) ................. SAE 75W-85W, 75W-90 API
GL-4 Or GL-5
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
\
\
\
\
\
\
\
Fluid Capacities
\
\
\
\
\
\
\
Application Quantity
Automatic Transmission
1987-93 ...................................... 7.6 Qts. (7.2L)
1994 (3.0L SOHC) ............................. 7.6 Qts. (7.2L) \
1994 (3.0L DOHC & 3.5L) ...................... 9.0 Qts. (8.5L) \
1995 ......................................... 7.9 Qts. (7.5L)
Cooling System
1987-88 ...................................... 8.5 Qts. (8.0L)
1989-95
2.6L ........................................ 9.7 Qts. (9.2L)
3.0L ....................................... 10.0 Qts. (9.5L)
1994-95
3.5L ....................................... 10.0 Qts. (9.5L)
Differential
Page 720 of 1333
![MITSUBISHI MONTERO 1991 Service Manual Fluid Capacities
\
\
\
\
\
\](/manual-img/19/57332/w960_57332-719.png "MITSUBISHI MONTERO 1991 Service Manual Fluid Capacities
\
\
\
\
\
\")
Fluid Capacities
\
\
\
\
\
\
\
Application Quantity
Engine Oil
1987 ......................................... 5.2 Qts. (5.0L)
1988 ......................................... 5.0 Qts. (4.8L)
1989-92 ...................................... 5.5 Qts. (5.3L)
1993-95 ...................................... 5.2 Qts. (4.9L)
\
\
\
\
\
\
\
\f
105,000 MILE (168,000 KM) SERVICE
105,000 MILE (168,000 KM) SERVICE \
\
\
\
\
\
\
Service Or Inspect
\
\
\
\
\
\
\
Verify Last Major Service Was Performed
\b\
\
\
\
\
\
\
Fluid Levels
\b\
\
\
\
\
\
\
Braking System
\b\
\
\
\
\
\
\
Drive Shaft Boots
\
\
\
\
\
\
\
Replace
\
\
\
\
\
\
\
Engine Oil
\b\
\
\
\
\
\
\
Oil Filter
\
\
\
\
\
\
\
Lubrication Specifications
\
\
\
\
\
\
\
Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ........... SAE 90, 85W-90, 80W-90
API GL-5
Maximum Temperature
Less Than -30
F (-34
C) .................... SAE 75W API GL-5
Power Steering Fluid ............................. Dexron-II ATF
Rear Axle (With Limited
Slip Differential) ............ Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic ...................................... Dexron-II ATF
Manual Transaxle &
Transfer Case (4WD) ................. SAE 75W-85W, 75W-90 API
GL-4 Or GL-5
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
Page 723 of 1333
![MITSUBISHI MONTERO 1991 Service Manual Manual Transmission Oil & Transfer Case
\b\
\
\
\
\
\](/manual-img/19/57332/w960_57332-722.png "MITSUBISHI MONTERO 1991 Service Manual Manual Transmission Oil & Transfer Case
\b\
\
\
\
\
\")
Manual Transmission Oil & Transfer Case
\b\
\
\
\
\
\
\
Carburetor Choke Mechanism & Linkage (2.6L Engine)
\b\
\
\
\
\
\
\
Crankcase Emission Control System (PCV Valve)
\b\
\
\
\
\
\
\
Evaporative Emission Control System
\b\
\
\
\
\
\
\
Distributor Cap, Rotor & Spark Advanced System
\b\
\
\
\
\
\
\
Intake Temperature Control System
\b\
\
\
\
\
\
\
Secondary Air System
\b\
\
\
\
\
\
\
Front Disc Pads
\b\
\
\
\
\
\
\
Rear Drum Brake Linings & Wheel & Cylinders
\b\
\
\
\
\
\
\
Brake Hoses
\b\
\
\
\
\
\
\
Steering Linkage Seals & Drive Shaft Boots
\b\
\
\
\
\
\
\
Lubricate Ball Joints
\b\
\
\
\
\
\
\
Lubricate Front Wheel Bearing
\b\
\
\
\
\
\
\
Drive Axle Fluid (Without Limited-Slip Differential)
\b\
\
\
\
\
\
\
Lubricate Drive Shaft Joints
\b\
\
\
\
\
\
\
Exhaust System
\b\
\
\
\
\
\
\
Drive Belt (Water Pump & Alternator)
\b\
\
\
\
\
\
\
Vacuum, Water, Crankcase Ventilation & Secondary Air Hoses
\
\
\
\
\
\
\
Replace
\
\
\
\
\
\
\
Air Filter
\b\
\
\
\
\
\
\
Fuel Filter
\b\
\
\
\
\
\
\
Spark Plugs
\b\
\
\
\
\
\
\
Ignition Cables
\b\
\
\
\
\
\
\
Camshaft Timing Belt
\b\
\
\
\
\
\
\
Engine Coolant
\b\
\
\
\
\
\
\
Drive Axle Fluid (With Limited-Slip Differential)
\b\
\
\
\
\
\
\
Engine Oil & Filter
\b\
\
\
\
\
\
\
Automatic Transmission & Transfer Case Fluids
\b\
\
\
\
\
\
\
Vacuum Control System Solenoid Valve Air Filter
\
\
\
\
\
\
\
Lubrication Specifications
\
\
\
\
\
\
\
Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Page 725 of 1333
![MITSUBISHI MONTERO 1991 Service Manual 1987-91 ...................................... 2.3 Qts. (2.2L)
1992-95 ...................................... 2.4 Qts. (2.3L)
\
\](/manual-img/19/57332/w960_57332-724.png "MITSUBISHI MONTERO 1991 Service Manual 1987-91 ...................................... 2.3 Qts. (2.2L)
1992-95 ...................................... 2.4 Qts. (2.3L)
\
\")
1987-91 ...................................... 2.3 Qts. (2.2L)
1992-95 ...................................... 2.4 Qts. (2.3L)
\
\
\
\
\
\
\
Service Labor Times
\
\
\
\
\
\
\
Application Hours
30,000 (60,000) 50,000
Application Mile Service Mile Service
2.6L 4-Cylinder
Automatic Transmission .... 7.9 (8.9) ................. 2.6
Manual Transmission ....... 6.9 (7.9) ................. 2.6
3.0L V6
Automatic Transmission .... 6.1 (10.6) ................ 2.6
Manual Transmission ....... 5.1 (9.6) ................. 2.6
\
\
\
\
\
\
\
\f
LUBRICATION SPECIFICATIONS TABLE\
\
\
\
\
\
\
Application Fluid Specifications
Brake & Clutch Fluid ........................... DOT 3 Or DOT 4
Engine Coolant ............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ..... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) .. SAE 10W-30 Or 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) ......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ..... SAE 85W-90, 80W-90 API GL-5
Maximum Temperature
Less Than -30
F (-34
C) ................... SAE 75W API GL-5
Power Steering Fluid ........................... Dexron-IIE ATF
Rear Axle (With Limited
Slip Differential) ........... Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic .................................... Dexron-IIE ATF
Manual Transaxle &
Transfer Case (4WD) ........... SAE 75W-85W, 75W-90 API GL-5
( 1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
\
\
\
\
\
\
\
FLUID CAPACITIES
FLUID CAPACITIES TABLE\
\
\
\
\
\
\
Application Quantity
A/C System R-12 Refrigerant
1983-87 .......................................... 24-26 Ozs.
1988-91 ............................................. 32 Ozs.
1992-93 ............................................. 28 Ozs.
A/C System R-134a Refrigerant ( 1)
1994-95 .......................................... 21-23 Ozs.
Automatic Transmission
Page 747 of 1333
STA R TE R
1991 M it s u bis h i M onte ro
ELECTRICAL
Starters
Diamante, Eclipse, Expo/Expo LRV, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
DESCRIPTION
Starter is a conventional 12-volt, 4-pole brush-type motor,
with direct or gear reduction drive. The starter-mounted solenoid
shifts overrunning clutch and pinion into flywheel when starter is
energized.
TROUBLE SHOOTING
NOTE: See the TROUBLE SHOOTING - BASIC PROCEDURES article
in the GENERAL TROUBLE SHOOTING section.
NO LOAD TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Install starter in soft-jawed vise. Connect starter in
series with a fully charged 12-volt battery. Connect a 100-amp ammeter
and carbon pile rheostat in series with positive battery post and
starter motor terminal. See Fig. 1.
2) Install voltmeter across starter motor. Adjust carbon pile
rheostat to full resistance. Connect cable from starter motor body to
negative battery terminal. Adjust carbon pile rheostat to proper test
voltage. See STARTER NO LOAD SPECIFICATIONS table.
3) Note that maximum amperage is within specification and
starter rotates smoothly. See STARTER NO LOAD SPECIFICATIONS table.
Fig. 1: Starter No Load Test Connections
Courtesy of Chrysler Motors.
STARTER NO LOAD SPECIFICATIONS
Page 750 of 1333
Remove negative battery cable. If necessary, raise vehicle on
hoist. Remove starter mounting bolts and starter. To install, reverse
removal procedure.
NOTE: On Raider models with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP CHECK in this article.
DISASSEMBLY
NOTE: Procedures may vary slightly between conventional and
reduction gear starters.
1) Loosen nut securing connecting plate-to-magnetic switch
"M" terminal. Remove screws securing magnetic switch and remove switch
(solenoid) assembly. Remove through bolts and brush cover assembly.
Tap yoke assembly loose with wooden mallet. Remove yoke, armature
assembly and pinion shift lever.
2) Remove pinion stop ring from end of armature shaft by
pushing stop ring to clutch side. Remove snap ring and overrunning
clutch assembly from armature shaft.
Fig. 4: Disassembled View of Typical Mitsubishi Starter
CLEANING & INSPECTION
Clean all parts. Do not use grease dissolving solvent on
Page 751 of 1333
overrunning clutch, armature assembly, solenoid assembly or field
coils due to possible damage. Inspect all parts for damage or wear and
replace as required.
BENCH TESTS
Brushes & Springs
Check brush spring tension using a spring scale. Check brush
contact surface condition and brush length. Check lead clip and wire
connections and condition of brush holders. Replace as required. See
Brush Spring Tension and Minimum Brush Length Charts.
BRUSH & SPRING SPECIFICATIONS
BRUSH SPRING TENSION \
\
\
\
\
\
Application Ozs. (g)
Chrysler Corp. Imports ............ 46-59 (1302-1670)
\
\
\
\
\
\
MINIMUM BRUSH LENGTH ( 1) \
\
\
\
\
\
Application In. (mm)
Chrysler Corp. Imports ................... .45 (11.5)
(1) - Minimum brush length should coincide with the
brush wear mark.
\
\
\
\
\
\
Armature
Check external condition of armature for scoring or other
damage. Measure shaft distortion with dial indicator. Replace armature
if shaft distortion exceeds .004" (.10 mm).
Commutator
1) Inspect commutator for roughness, grooves, burns or
pitting. Sand lightly with 500 grit sandpaper if necessary. Check
commutator for out-of-round and mica insulators undercut to a depth of
.020-.031" (.5-.8 mm).
2) If necessary, commutator may be turned less than .04" (1
mm) from original size and mica undercut. Replace if excessively worn.
Field Coil
1) Check field coil continuity by connecting test probe of
circuit tester or an ohmmeter to the field coil positive terminal and
brush holder. If circuit is open, replace field coil.
2) Check for grounding of field coils by placing one probe of
circuit tester on starter housing and other probe to field coil
positive terminal. If little or no resistance, field coil is grounded
and must be replaced.
Overrunning Clutch Assembly
1) Inspect pinion assembly and sleeve. Sleeve should slide
freely on armature shaft and spline. If damage or resistance is noted,
replace assembly.
2) Check pinion and flywheel teeth for excessive rubbing or
damaged teeth. Replace as required.
Pinion Gear Clearance
The clearance between the pinion gear and pinion stopper