1991 MITSUBISHI MONTERO height

CAMSHAFT TABLE (SOHC)








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Application In. (mm)
End Play
Standard ........................... .004-.008 (0.1-0.2)
Limit ....................................... .015 (0.4)
Journal Diameter ............................. 1.34 (34.0)
Lobe Height
Standard ................................. 1.624 (41.25)
Limit .................................... 1.604 (40.75)
Oil Clearance .................... .0020-.0035 (.050-.090)









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CAMSHAFT SPECIFICATIONS (DOHC)
CAMSHAFT TABLE (DOHC)








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Application In. (mm)
End Play
Standard ........................... .004-.008 (0.1-0.2)
Limit ....................................... .015 (0.4)
Journal Diameter ............................ 1.024 (26.0)
Lobe Height
Intake
Standard ................................ 1.397 (35.49)
Limit ................................... 1.378 (34.99)
Exhaust
Standard ................................ 1.386 (35.20)
Limit ................................... 1.366 (34.70)
Oil Clearance .................... .0020-.0035 (.050-.090)









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BRAK E S YSTE M

1991 M it s u bis h i M onte ro
1991 BRAKES
Disc & Drum
Chrysler Motors: Ram-50;
Mitsubishi: Montero, Pickup
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake unit, proportioning valve and self-adjusting assembly. Pickup
and Ram-50 models have a Load-Sensing Proportioning Valve (LSPV). All
models are equipped with front disc brakes and rear drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Montero
Bleed brake system in following order: right rear, right
front and left front (one circuit handles both rear brakes).
Pickup & Ram-50
Bleed brake system in following order: right rear, left rear,
LSPV, right front and left front.
ADJUSTMENTS
BRAKE PEDAL HEIGHT & FREE PLAY
1) Separate connector from stoplight switch, and loosen lock
nut. Position switch so it does not contact brake pedal arm. Adjust
brake pedal height by rotating master cylinder push rod (yoke, if
equipped) until distance from top of brake pedal to floor board is
correct. See BRAKE PEDAL SPECIFICATIONS table.
2) DO NOT depress push rod. Tighten lock nut, and ensure
brake pedal height is within specification. Start engine to evacuate
brake booster chamber. Stop engine, and apply brake several times to
remove vacuum from brake booster.
3) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. If distance is incorrect, bleed the
brake hydraulic system, and check for misadjusted brakes. Refer to the
BRAKE PEDAL SPECIFICATIONS table.
BRAKE PEDAL SPECIFICATIONS TABLE









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Free Play Pedal Height
Application In. (mm) In. (mm)
Montero ............ .12-.31 (3-8) ... 7.5-7.7 (191-196)
Pickup & Ram-50 .... .12-.31 (3-8) ........... 6.5 (166)









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LOAD-SENSING PROPORTIONING VALVE (LSPV) (Pickup & Ram-50)
Park vehicle on level surface. Remove all luggage and
passengers. Ensure lever is not against stopper bolt. Check spring

length. If spring length is not 6.97-7.09 in. (177-180 mm), adjust
cable or support until correct length is obtained. See Fig. 1.
Fig. 1: Testing LSPV Spring Length (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
MASTER CYLINDER PUSH ROD
Check and adjust clearance between back of master cylinder
piston and power brake push rod. See PUSH ROD CLEARANCE SPECIFICATIONS
table. See Fig. 2. After adjusting push rod clearance, adjust pedal
height, and bleed brake system.
Fig. 2: Adjusting Push Rod Clearance
Courtesy of Mitsubishi Motor Sales of America.
PUSH ROD CLEARANCE SPECIFICATIONS TABLE









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brake pedal to center shoes, and check pedal travel. Rotate brake drum
to verify free movement.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
.02-.04" (.5-1.0 mm). Tighten lock nut. DO NOT depress master cylinder
push rod during stoplight switch adjustment.
TESTING
POWER BRAKE UNIT
Check Valve Inspection
Remove vacuum hose from power brake unit. Remove check valve
from hose (if possible). Using a vacuum pump, ensure airflow is in
direction of intake manifold only.
System Check
1) Run engine for 2 minutes, and shut it off. Depress brake
pedal several times with normal pressure. If pedal height gradually
becomes higher with successive applications, power brake unit is okay.
If pedal height remains steady, power brake unit is faulty.
2) With engine stopped, depress brake pedal repeatedly until
it's height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake unit is okay. If pedal
height does not change, power brake unit is faulty.
3) With engine running, press and hold brake pedal and shut
off engine. Hold brake pedal for 30 seconds. Brake pedal height should
not change. If pedal height falls, power brake unit is faulty.
LOAD-SENSING PROPORTIONING VALVE (LSPV) (PICKUP & RAM-50)
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
,
ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, perform LSPV
test beginning with next step.
2) Ensure unladen vehicle is on level ground. Ensure lever is
not contacting stopper bolt. See Fig. 1.
3) When lever is pushed toward valve, distance from LSPV
lever hole and support hole must be 6.97-7.09 in. (177-180 mm). If
measured distance is not within specification, loosen support bolt.
Adjust support until measured distance is within specification.
4) After measured distance is within specification, connect
pressure gauges to input and output ports of LSPV. See Fig. 4. Bleed
brake system. See BLEEDING BRAKE SYSTEM .
Fig. 4: Connecting Pressure Gauges to LSPV (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.

Installation
To install, reverse removal procedure. Tighten wheel bearings
to 22 ft. lbs. (30 N.m). Loosen nut, and then retighten to 72 INCH
lbs. (8 N.m). Install cotter pin. If pin does not align, loosen nut up\
to a maximum of 30 degrees.
REAR BRAKE DRUM & SHOES
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Remove shoe return spring and brake shoe adjuster. See Fig. 8. Remove
adjusting spring, shoe retaining spring and shoe hold-down pins.
2) Remove shoe and lining assembly with parking brake lever.
Remove cable from parking lever. Remove parking brake lever snap ring,
and disengage lever from brake shoe.
Fig. 8: Exploded View of Rear Brake Assembly
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) To install, reverse removal procedure. Apply Lubriplate to
backing plate bosses, adjuster assembly threads and parking brake
lever pin.
2) Set adjustment assembly so brake shoes lightly contact
brake drum. Depress brake pedal to center shoes, and check pedal
travel. Rotate brake drum to ensure free movement.
WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES under REMOVAL & INSTALLATION. Remove wheel
cylinder and seal assembly. To install, reverse removal procedure.
Bleed brakes.
MASTER CYLINDER
Removal
Drain brake fluid from master cylinder. Remove sensor
connector (if equipped). Disconnect brake lines from master cylinder,
and install plugs to prevent brake fluid spillage. Remove master
cylinder from booster unit and separate reservoirs from housing (if
necessary).
Installation
To install, reverse removal procedure. Before installation,
check and adjust clearance between back of master cylinder piston and
power brake push rod. Refer to MASTER CYLINDER PUSH ROD under
ADJUSTMENTS. After installation, adjust the brake pedal height. Refer
to BRAKE PEDAL HEIGHT & FREE PLAY under ADJUSTMENTS. Bleed brake
system. See BLEEDING BRAKE SYSTEM .

1) Install pinion bearing races in carrier. For front race
use Handle (MB990938-01) and Race Installer (MB990934-01) for 2.4L a\
nd
2.6L models and Race Installer (MB990935-01) for 3.0L models. For rear\
race, use Handle and Race Installer (MB990936-01). Ensure races are
fully seated.
2) Install Pinion Height Gauge (MB990901-01) and pinion
bearings. See Fig. 4. DO NOT install oil seal. Using INCH lb. torque
wrench, measure pinion rotating torque. Gradually tighten pinion
height gauge to increase rotating torque to proper specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
3) Install Cylinder Gauge (MB990903-01) in side bearing
seats. Ensure flat areas are aligned and gauge contacts side bearing
seat firmly. See Fig. 4.
4) Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge. Use minimum amount of
adjusting shims. Install selected adjusting shims between drive pinion
gear and rear pinion bearing. Using Bearing Installer (MB990802-01),
install rear pinion bearing.
PINION ROTATING TORQUE SPECIFICATIONS









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Application INCH Lbs. (N.m)
With Oil Seal
2.4L & 2.6L Engines . 3.04-3.91 (.35-.45)
3.0L Engine ........... 5.21-6.08 (.6-.7)
Without Oil Seal
2.4L & 2.6L Engines . 1.30-2.17 (.15-.25)
3.0L Engine ........... 3.47-4.34 (.4-.5)









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Fig. 4: Setting Pinion Depth
Courtesy of Chrysler Motors.
DRIVE PINION PRELOAD

PROBLEM
Possible Cause Action









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GREASE LEAKING
Ripped CV Boot ................................... Replace Boot
CLICKING NOISE WHILE CORNERING
Dry/Worn CV Joints .................... Replace Outer CV Joints
CLUNK ON ACCELERATION
Dry/Worn CV Joints .................... Replace Inner CV Joints
Worn Trans. Gears/Bearings ..................... Inspect Trans.
VIBRATION/SHUDDER ON ACCELERATION
Dry/Worn CV Joints .......................... Replace CV Joints
Alignment Out ................................. Check Alignment
Incorrect Spring Height ................... Check Spring Height
SQUEALING OR HUMMING
Dry/Worn CV Joints ..................... Lube/Replace CV Joints
Faulty Wheel Bearing .................... Replace Wheel Bearing









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TESTING & INSPECTION
AXLE SHAFT END PLAY
Using dial indicator, check axle shaft end play. End play
must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shims to obtain correct end play. See AXLE
SHAFTS under REMOVAL & INSTALLATION.
AXLE TOTAL BACKLASH
1) Raise and support rear axle. Place transmission in
Neutral. Apply parking brake. Rotate drive shaft clockwise. Place
reference marks on pinion dust cover and differential housing.
2) Rotate drive shaft counterclockwise and measure distance
between reference marks. Differential must be removed and backlash
adjusted if distance exceeds 0.2" (5.0 mm).
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel free of ground and remove wheel. Use Axle Puller
Adapter (MB990241) for Montero and Pickup models. Install adapter on
wheel studs. Release parking brake.
2) Using torque wrench, measure starting torque on Pickup
models while rotating wheel in forward direction. On Montero models,
measure rotating torque. This measurement is read once axle is
turning. Differential must be repaired if torque is less than
specification. See TESTING SPECIFICATIONS table.

Fig. 10: Checking Differential Starting Torque
Courtesy of Chrysler Motors.
14) Starting torque must be within specification. See
STARTING TORQUE SPECIFICATIONS table. Ensure adhesive is removed from
ring gear mounting bolts and gear mounting surface. Clean internal
threads with tap.
15) Ensure alignment marks on differential case and ring gear
are aligned. Apply Loctite 271 to bolts and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS table.
STARTING TORQUE SPECIFICATIONS









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Application Ft. Lbs. (N.m)
Used Clutch Plates .................. 25-72 (34-98)
New Clutch Plates ................... 47-72 (64-98)









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DRIVE PINION HEIGHT
1) Install pinion bearing races in carrier. Ensure races are
fully seated. Install pinion height gauge and pinion bearings. Use
Pinion Height Gauge (MB990901) for all others. See Fig. 10. DO NOT
install oil seal.
2) Using torque wrench, measure pinion rotating torque.
Gradually tighten pinion height gauge to increase rotating torque to
3.5-4.3 INCH lbs. (.40-.48 N.m).
3) Install cylinder gauge in side bearing seats. Ensure flat
areas are aligned and gauge contacts side bearing seat firmly. See
Fig. 11 . Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected