1991 MITSUBISHI MONTERO clutch

Fig. 10: Manual Transmission & Clutch

2) Remove 2 seal plugs. Remove 2 poppet springs and steel
balls. Shift transfer case to "4WD" and pull high-low shift rail out,
in rear cover direction. Remove interlock plunger. Remove pulse
generator (if equipped), front output shaft cover and pulse rotor (if\
equipped). Remove snap ring from rear bearing on output shaft. Remove
chain cover, oil guide and side cover. Remove countershaft locking
plate. Remove countershaft.
3) Remove countergear, 2 thrust washers, 2 needle bearings
and spacer through side cover opening. Remove snap ring, spring
retainers and spring from 2WD-4WD shift rail. Remove front output
shaft, rear output shaft and chain as assembly.
4) Remove 2WD-4WD shift fork and distance piece. Drive out
2WD-4WD shift rail spring pin. Remove 2WD-4WD shift rail and lug.
Remove high-low shift fork and high-low synchronizer sleeve. Remove
needle bearing and snap ring from input gear. Remove input gear
assembly.
5) If either control shaft or input gear oil seals are to be
replaced, drive out roll pin from transmission control change shifter.
Separate transfer case from adapter. See Fig. 3.
Disassembly (Montero)
1) Remove dynamic damper, 5 detection switches and 3 steel
balls. Remove poppet plug, spring and steel ball. Remove speedometer
gear assembly. Remove output shaft rear cover, spacers, dust seal
guard and oil seals. Front output shaft cover, wave spring and spacer
(if equipped).
2) Remove high-low shift rail plug and high-low shift fork
spring pin. Shift transfer case to "4WD". Remove rear cover and high-
low shift rail. Remove interlock plunger. Remove rear output shaft
(viscous coupling) assembly and center differential assembly. Remove
2WD-4WD synchronizer assembly, chain and front output shaft from
transmission as a unit. With White paint make match marks in grooves
of 2WD-4WD synchronizer in 3 places. With White paint make match marks
on spline projections of 2WD-4WD synchronizer sleeve in 3 places.
Refer to match marks during reassembly.
3) Remove snap ring, spring seat, spring, 2WD-4WD shift fork
and 2WD-4WD synchronizer sleeve. Remove differential lock hub, oil dam
cover and bearing retainer. Remove side cover and gasket. Remove
transfer counter gear shaft, transfer counter gear, thrust washer,
needle bearings and spacer. Remove transfer drive shaft assembly.
Remove high-low shift fork assembly and clutch sleeve. Remove transfer
input gear assembly.
4) Remove 2WD-4WD shift lug spring pin, spring, spring
retainer 2WD-4WD shift lug and shift rail. Remove input gear oil seal,
baffle plate, dust seal guard and front output shaft oil seal. See
Fig. 4 .
COMPONENT DISASSEMBLY & REASSEMBLY
OUTPUT SHAFT ASSEMBLY (MONTERO)
Disassembly & Reassembly (Rear Shaft)
Remove snap ring and press ball bearing off without putting
pressure on vicious coupling. Remove viscous coupling. To install,
reverse removal procedure. When installing new snap ring, select
thickest ring that will fit into groove. Acceptable clearance is 0-.
003" (0-.08 mm).
Disassembly & Reassembly (Front Shaft)
Remove front bearing. Remove rear bearing. To install reverse
removal procedure.

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TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - A /T
1991 M it s u bis h i M onte ro
199192 TRANSMISSION SERVICING
Transmission Removal & Installation
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
MANUAL
NOTE: For manual transmission/transaxle replacement procedures,
see appropriate article in CLUTCHES.
AUTOMATIC FWD MODELS
REMOVAL
1) Remove battery and battery tray. On 3000GT, remove
undercover(s). On Eclipse turbo, drain and remove intercooler. On all
models, remove air cleaner and case. Raise and support vehicle. Remove
wheels. Disconnect control cables at transaxle. Drain transaxle fluid.
2) On Mirage 1.6L, disconnect tension rod. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) On Galant models with electronically controlled
suspension, remove air compressor and bracket. Disconnect front height
sensor rod at lower control arm.
4) On all models, remove upper transaxle-to-engine bolts.
Remove engine undercover (if equipped). On all models, remove drive
axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Separate
lower control arms from struts for access to axle shafts (if
necessary).
5) Remove front exhaust pipe (if necessary). On Eclipse 4WD,\
Galant 4WD and 3000GT, remove right member and gusset. On 4WD models,
separate transfer assembly from transaxle. Reference mark transfer
assembly-to-drive shaft and remove transfer assembly.
6) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
7) Support transaxle with jack. Remove transaxle mounts
bolts, mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
INSTALLATION
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. Adjust all control cables.
RWD MODELS

specification, use the following trouble shooting guide.
* Hydraulic Pressure High In All Ranges
Check throttle cable adjustment. If adjustment is okay, check
for throttle valve or regulator valve failure.
* Hydraulic Pressure Low In All Ranges
Check throttle cable adjustment. If adjustment is okay, check
for throttle valve, regulator valve, transmission oil pump or
overdrive clutch failure.
* Hydraulic Pressure Low In Drive Position
Check for fluid leaks in Drive hydraulic circuit. Check for
forward clutch or overdrive clutch failure.
* Hydraulic Pressure Low In Reverse Position
Check for fluid leaks in Reverse hydraulic circuit. Check for
transmission No. 3 brake failure, forward clutch failure or
overdrive clutch failure.
LINE PRESSURE (PICKUP)
1) Incorrect throttle pressure setting will cause incorrect
line pressure readings even though line pressure adjustment is
correct. Always inspect and correct throttle pressure adjustment
before adjusting line pressure.
2) Approximate adjustment, measured from valve body to inner
edge of adjusting nut, is 15/16". However, due to manufacturing
tolerances, adjustment can be varied to obtain correct line pressure.
3) Adjusting screw may be turned with an Allen wrench. One
complete turn of adjusting screw changes closed throttle line pressure
approximately 1 2/3 psi. Turn adjusting screw counterclockwise to
increase pressure or clockwise to decrease pressure.
THROTTLE PRESSURE (PICKUP)
1) Throttle pressures cannot be accurately tested. If a
malfunction exists, adjustment should be measured.
2) Insert Gauge Pin (C-3763) between throttle lever cam and
kickdown valve. Push in on tool to compress kickdown valve against its
spring.
3) As force is being exerted to compress spring, turn
throttle lever screw with Allen wrench until head of screw touches
throttle lever tang with gauge pin, and throttle valve bottoms. Ensure
adjustment is made with spring fully compressed and valve bottomed in
valve body.
KICKDOWN BAND
PICKUP
1) Locate kickdown band adjusting screw on left side of
transmission case. Loosen lock nut, and back off nut 5 turns. Ensure
adjusting screw turns freely in transmission case.
2) Using torque wrench, tighten adjusting screw to 72 INCH
lbs. (8 N.m). Back off adjusting screw 2 7/8 turns. Hold adjuster
screw in this position, and tighten lock nut to 30 ft. lbs. (41 N.m).
LOW-REVERSE BAND
PICKUP
1) Raise vehicle, drain transmission, and remove oil pan.
Loosen adjusting screw lock nut, and back off nut 5 turns. Ensure

KM200 ................................... 3.6 (1.7)
KM201 ................................... 3.8 (1.8)
3000GT (AWD) .............................. 5.0 (2.4)









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TRANSFER CASE REFILL CAPACITIES TABLE








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Application Pts. (L)
Eclipse .............................. 1.5 (0.7)
Montero & Pickup ..................... 4.7 (2.2)
Eclipse .............................. 1.5 (0.7)
Galant ............................... 1.3 (0.6)
Montero & Pickup ..................... 4.6 (2.2)
3000GT ................................. .6 (.3)









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SELECT CABLE ADJUST
GALANT, MIRAGE & SIGMA
1) With transaxle select lever in Neutral, move gearshift
lever into 4th gear. It may be necessary to depress clutch pedal.
2) Loosen selector cable adjuster nuts (inside of vehicle).
See Fig. 2 . With select lever in Neutral, adjust select cable end
until eye fits easily over select lever pin. Tighten adjuster nuts.
SHIFT CABLE & GEARSHIFT LEVER ADJUST
GALANT, MIRAGE & SIGMA
1) With transaxle select lever in Neutral, move gearshift
lever into 4th gear. It may be necessary to depress clutch pedal.
2) Loosen shift cable adjuster nuts (inside of vehicle) and
disconnect cable end from shift lever pin. Tilt gearshift lever into
4th gear position until it touches stopper. See Fig. 3. Hold lever in
this position and adjust shift lever cable so cable aligns with shift
lever pin.
3) Move shift lever between 3rd, Neutral and 4th gear
positions. Shift lever-to-stopper clearances should be equal on both
sides of lever. See Fig. 3. If clearances "A" and "B" are not equal,
readjust shift cable. Road test vehicle to ensure proper adjustment
and smooth shifting.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Drain Plug & Filler Plug
Eclipse, Galant & Mirage ............. 22-25 (30-34)
Montero, Pickup ..................... 22-25 (30-34)
4WD 3.0L ............................ 40-61 (54-83)
Precis & 3000GT ................................ ( 1)
( 1) - Information is not available from manufacturer.









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Open solenoid pull-in See Testing in STARTER
wire article









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Starter Does Not Weak battery or dead Charge or replace
Operate and cell battery as necessary
Headlights Dim
Loose or corroded battery Check that battery
connections connections are clean
and tight
Internal ground in See Testing in STARTER
starter windings article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article
shoes









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Starter Turns Starter clutch slipping See STARTER article
but Engine
Does Not Rotate
Broken clutch housing See STARTER article
Pinion shaft rusted or See STARTER article
dry
Engine basic timing See Ignition Timing in
incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and
flywheel check for starter pinion
gear damage









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Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and
check for starter pinion
gear damage
Armature shaft sheared See STARTER article
or reduction gear teeth
stripped
Weak battery Charge or replace
battery as necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground
connections for
tight and clean
connections
Ignition switch faulty Adjust or replace
or misadjusted ignition switch as
necessary









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Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary

Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter









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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article









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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid









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Starter Relay Dead battery Charge or replace
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay

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Starter Drive Starter motor loose on Tighten starter
Will Not mountings attach bolts
Disengage
Worn drive end bushing See STARTER article
Damaged engine flywheel Replace flywheel and
teeth starter pinion gear for
damage
Drive yolk return spring Replace return spring
broken or missing
Faulty ignition switch Replace ignition switch
Insufficient clearance Replace starter
between winding leads to solenoid
solenoid terminal and main
contact in solenoid
Starter clutch not Replace starter clutch
disengaging
Ignition starter switch Replace ignition switch
contacts sticking









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Starter Relay Faulty solenoid switch, Check all wiring
Operates but switch connections or between relay and
Solenoid Does Not solenoid or replace
relay or solenoid as
necessary
Broken lead or loose Repair wire or wire
soldered connections connections as
necessary









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Solenoid Plunger Weak battery Charge or replace
Vibrates When battery as necessary
Switch is Engaged
Solenoid contacts Clean contacts or
corroded replace solenoid
Faulty wiring Check all wiring
leading to solenoid
Broken connections inside Repair connections or
switch cover replace solenoid
Open hold-in wire Replace solenoid









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Low Current Draw Worn brushes or weak Replace brushes or
brush springs as
necessary









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High Pitched Whine Distance too great Align starter or check
During Cranking between starter that correct starter
Before Engine pinion and flywheel and flywheel are being
Fires but Engine used
Fires and Cranks
Normally









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High Pitched Distance too small between
Whine After Engine starter pinion and flywheel