1991 MITSUBISHI MONTERO Service Manual

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Page 1185 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \003TR AN SM IS SIO N S ER VIC IN G - M /T 1991 M it s u bis h i M onte ro 1990-91 Manual Transmission Servicing Eclipse, Galant, Mirage, Montero, Pickup, Precis, Sigma$

\003TR AN SM IS SIO N S ER VIC IN G - M /T

1991 M it s u bis h i M onte ro
1990-91 Manual Transmission Servicing
Eclipse, Galant, Mirage, Montero, Pickup, Precis, Sigma
IDENTIFICATION
1990 MANUAL TRANSMISSION APPLICATIONS TABLE\
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Model Transmission
Eclipse
1.8L SOHC ..... 5-Speed - Model F5M22 Transaxle
1.8L DOHC ..... 5-Speed - Model F5M22 Transaxle
2.0L DOHC
Turbo ........ 5-Speed - Model F5M33 Transaxle
Galant ......... 5-Speed - Model KM206 Transaxle
Mirage
1.5L ......... 5-Speed - Model KM201 Transaxle
1.6L ......... 5-Speed - Model KM210 Transaxle
Montero
2.6L ................... 5-Speed - Model KM145
3.0L ................... 5-Speed - Model V5MT1
Pickup
2WD .................... 5-Speed - Model KM132
4WD .................... 5-Speed - Model KM145
Precis ......... 4-Speed - Model KM161 Transaxle
5-Speed - Model KM163 Transaxle
Sigma .......... 5-Speed - Model KM210 Transaxle
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1991 MANUAL TRANSMISSION APPLICATIONS TABLE\
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Model Transmission
Eclipse
2.0L ............... 5-Speed Transaxle (F5M22)
2.0L (Turbo) ....... 5-Speed Transaxle (F5M33)
Galant
2WD ................ 5-Speed Transaxle (F5M22)
AWD
DOHC ............. 5-Speed Transaxle (W5M31)
DOHC (Turbo) ..... 5-Speed Transaxle (W5M33)
Mirage
1.5L ............... 4-Speed Transaxle (F4M21)
5-Speed Transaxle (F5M21)
1.6L ............... 5-Speed Transaxle (F5M22)
Montero ........... 5-Speed Transmission (V5MT1)
Pickup
2WD ............. 5-Speed Transmission (R5M21)
4WD ............. 5-Speed Transmission (V5MT1)
Precis ............... 4-Speed Transaxle (KM200)
5-Speed Transaxle (KM201)
3000GT
2WD ................ 5-Speed Transaxle (F5M33)
AWD ................ 5-Speed Transaxle (W5MG1)
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LUBRICATION SERVICE INTERVALS

Page 1186 of 1333

MITSUBISHI MONTERO 1991 Service Manual Check transaxle/transmission and transfer case fluid level
every 30,000 miles. Change fluid at 30,000 miles if operated under
severe service conditions.
CHECKING FLUID LEVEL

Check transaxle/transmission and transfer case fluid level
every 30,000 miles. Change fluid at 30,000 miles if operated under
severe service conditions.
CHECKING FLUID LEVEL
TRANSAXLE/TRANSMISSION
Lubricant level is checked at fill hole on side of transaxle
or transmission. Lubricant must be at bottom of fill hole.
TRANSFER CASE
Transfer case contains separate drain and fill plugs.
Lubricant must reach to bottom of fill hole.
On 3000GT models, transfer case contains separate drain and
fill plugs. Lubricant should be .5" (13 mm) from bottom of fill hole.
RECOMMENDED FLUID
Use API GL-4 or GL-5 SAE 75W-85 gear oil.
FLUID CAPACITY SPECS TABLE
TRANSMISSION REFILL CAPACITIES TABLE\
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Application Pts. (L)
Eclipse
F5M22 .............................. 3.8 (1.8)
F5M33 .............................. 4.7 (2.2)
Galant ............................... 3.8 (1.8)
Mirage
KM201 .............................. 3.8 (1.8)
KM210 .............................. 4.4 (2.0)
Montero
2.6L ............................... 4.7 (2.2)
3.0L ............................... 5.3 (2.6)
Pickup
2WD ................................ 4.9 (2.4)
4WD ................................ 4.7 (2.2)
Precis ............................... 4.4 (2.0)
Sigma ................................ 5.2 (2.5)
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1991 TRANSMISSION REFILL CAPACITIES\
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Application Pts. (L)
Mirage (1.5L)
F4M21 ................................... 3.6 (1.7)
F5M21 ................................... 3.8 (1.8)
Eclipse, Galant (2WD) & Mirage (1.6L) ..... 3.8 (1.8)
Eclipse (Turbo) & 3000GT (2WD) ............ 4.9 (2.3)
Galant (AWD) .............................. 4.9 (2.3)
Montero & Pickup .......................... 5.2 (2.5)
Pickup .................................... 4.9 (2.3)
Pickup .................................... 4.6 (2.2)
Precis

Page 1187 of 1333

$MITSUBISHI MONTERO 1991 Service Manual KM200 ................................... 3.6 (1.7) KM201 ................................... 3.8 (1.8) 3000GT (AWD) .............................. 5.0 (2.4) ��\ ��$

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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Page 1188 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 1: Typical Transaxle Control Cable
Courtesy of Chrysler Motors.
Fig. 2: Adjusting Select Cable
Courtesy of Chrysler Motors.

Page 1189 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 3: Adjusting Shift Cable
Courtesy of Chrysler Motors.

Page 1190 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \003 TR O UBLE S H O OTIN G - B ASIC P R O CED URES 1991 M it s u bis h i M onte ro GENERAL TROUBLE SHOOTING * PLEASE READ THIS FIRST * NOTE: This is GENERAL information$

\003
TR O UBLE S H O OTIN G - B ASIC P R O CED URES

1991 M it s u bis h i M onte ro
GENERAL TROUBLE SHOOTING
* PLEASE READ THIS FIRST *
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
ACCESSORIES & ELECTRICAL
CHARGING SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION\
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Vehicle Will Not Dead battery Check battery cells,
Start alternator belt
tension and alternator
output
Loose or corroded battery Check all charging
connections system connections
Ignition circuit or switch Check and replace as
malfunction necessary
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Alternator Light Loose or worn alternator Check alternator drive
Stays On With drive belt tension and
Engine Running condition, See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Loose alternator wiring Check all charging
connections system connections
Short in alternator light See Indicator Warning
wiring Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
Defective alternator stator See Bench Tests in
or diodes ALTERNATOR article
Defective regulator See Regulator Check in

Page 1191 of 1333

$MITSUBISHI MONTERO 1991 Service Manual ALTERNATOR article��\ ��\ ��\ ��\ ��\ ��\ ��$

ALTERNATOR article\
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Alternator Blown fuse See WIRING DIAGRAMS
Light Stays Off
With Ignition
Switch ON
Defective alternator See Testing in
ALTERNATOR article
Defective indicator light See Indicator Warning
bulb or socket Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
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Alternator Short in alternator wiring See On-Vehicle Tests
Light Stays OFF in ALTERNATOR article
With Ignition
Switch ON
Defective rectifier bridge See Bench Tests in
ALTERNATOR article
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Lights or Fuses Defective alternator wiring See On-Vehicle Tests
Burn Out in ALTERNATOR article
Frequently
Defective regulator See Regulator Check in
ALTERNATOR article
Defective battery Check and replace as
necessary
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Ammeter Gauge Loose or worn drive belt Check alternator drive
Shows Discharge belt tension and
condition. See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Defective wiring Check all wires and
wire connections
Defective alternator or See Bench Tests and
regulator On-Vehicle Tests in
ALTERNATOR article
Defective ammeter, or See Testing in
improper ammeter wiring STANDARD INSTRUMENTS
connection in the ACCESSORIES &
EQUIPMENT section
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Noisy Loose drive pulley Tighten drive pulley
Alternator attaching nut
Loose mounting bolts Tighten all alternator
mounting bolts
Worn or dirty bearings See Bearing
Replacement
ALTERNATOR article

Page 1192 of 1333

$MITSUBISHI MONTERO 1991 Service Manual Defective diodes or stator See Bench Test in ALTERNATOR article ��\ ��\ ��\ ��$

Defective diodes or stator See Bench Test in
ALTERNATOR article
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Battery Does Loose or worn drive belt Check alternator drive
Stay Charged belt tension and
condition. See
Belt Adjustment in
appropriate TUNE-UP
article in the
TUNE-UP section
Loose or corroded battery Check all charging
connections system connections
Loose alternator connections Check all charging
system connections
Defective alternator or See On-Vehicle Tests
battery and Bench Tests in
ALTERNATOR article
Add-on electrical accessories Install larger
exceeding alternator capacity alternator
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Battery Defective battery Check alternator
Overcharged- output and repair as
Uses Too Much necessary
Water
Defective alternator See On-Vehicle Test and
Bench Tests in
ALTERNATOR article
Excessive alternator voltage Check alternator output
and repair as necessary
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IGNITION SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
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START: Visually inspect Spark Plug Wires, Coil Wires,

Plug Wire Boots, Rotor, and Distributor Cap for

signs of damage.

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OK NOT OK
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* To test secondary ignition * Repair or replace

system, modify a Spark Plug damaged components

by attaching a ground wire as necessary

to the body of the plug and
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