1991 MITSUBISHI MONTERO parking brake

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.

TESTING SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Montero & Pickup ............................ 25 (34)









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REMOVAL & INSTALLATION
AXLE SHAFTS
Removal
1) Block front wheels. Raise and support rear axle housing.
Remove brake drum. See Fig. 1. Remove parking brake cable attaching
bolts. Remove connection for parking brake cable end and rear brake
assembly. Drain brake fluid from bleeder screw at left side of rear
brake and disconnect brake tubes.
2) On all models, remove flange nuts and rear axle shaft
assembly. Use Puller (MB990241) and Slide Hammer (MB990211) if
necessary. DO NOT damage oil seal. Remove shim(s) and "O" ring.
Replace if necessary.
Fig. 1: Exploded View of Axle Shaft
Courtesy of Chrysler Motors.
Installation
1) Insert a new "O" ring and a shim of .04" (1.0 mm)

thickness into left side axle housing. Install left axle shaft
assembly into axle housing and tighten nuts to specification. See
TORQUE SPECIFICATIONS table at the end of this article.
2) Install right axle shaft assembly into axle housing
WITHOUT a shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case and rear axle housing end with a feeler gauge.
3) Select shims equal to the sum of the thickness of the
measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle
shaft and install the selected shim(s) and "O" ring into right axle
housing end. Install right axle shaft assembly into rear axle housing.
Tighten nuts in diagonal sequence to specification. See TORQUE
SPECIFICATIONS table.
4) Using dial indicator, check end play of axle shaft. End
play must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake and bleed brake system.
DIFFERENTIAL CARRIER
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support
differential carrier with jack. Remove differential carrier retaining
nuts. Remove differential carrier.
Inspection
Inspect for leakage at vent plug, differential carrier
companion flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts. Remove drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.
OVERHAUL
AXLE SHAFTS
Disassembly
1) Mount backing plate and axle shaft assembly in soft-jawed
vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench
(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall\
lock nut on axle shaft approximately 3 turns.
2) Attach Bearing Puller (MB990787-01) to rear of backing
plate to remove bearing case from axle shaft. See Fig. 2. Using equal
pressure to avoid binding, tighten puller nuts diagonally to remove
bearing case. Using hammer and drift, remove bearing outer race from
bearing case. Remove oil seal from end of axle housing with Slide
Hammer and Adapter (MB990211).

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Component Component Location








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A/C Dedicated Fuse Behind right side of dash, on
evaporator case.
Central Door Lock Dedicated Fuse Behind right side of dash,
left of blower assembly.
Defogger Sub-Fusible Link On wiring harness, near front
wiper motor.
Dual A/C Dedicated Fuse Behind right side of dash, on
blower case.
Headlight Dedicated Fuse On left front corner of engine
compartment.
Fuse Block On left end side of dash, near
door.
Fusible Links:
Main On right rear corner of engine
compartment, near battery.
Sub On right rear corner of engine
compartment, near battery.
Sun Roof Dedicated Fuse Behind right side of dash.









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CONTROL UNITS








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Component Component Location








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Auto. Free Wheeling Hub Cntrl. Unit Behind right side of dash,
left of blower unit.
Cruise Control Unit Behind right kick panel.
Door Lock Control Unit Under center console, beside
parking brake lever.

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\

Light comes on with the ignition switch in the "ON" position
as a bulb check, but should go out shortly after engine is started. If
light remains on or comes on while driving, it indicates low oil
pressure and possible system malfunction. Have the system checked and
serviced immediately. Do not operate vehicle until cause is located
and corrected.
ALTERNATOR WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. If light remains
on or comes on while driving, it indicates possible fault in the
electrical charging system. The alternator belt may be loose or
broken. Have the system checked and serviced promptly. Do not drive
vehicle if alternator belt is loose or broken.
"BRAKE" WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. Light will also
come on with the parking brake fully or partially engaged. If light
remains on or comes on at any other time, it indicates low brake fluid
level in the master cylinder reservoir or the parking brake switch may
be damaged. Have the system checked and serviced immediately if brake
fluid level is low. Do not continue driving if further trouble is
experienced.
"CHECK ENGINE" WARNING LIGHT (IF EQUIPPED)
Light is designed to come on briefly with the ignition switch
in the "ON" position as a bulb check. If light remains on or comes on
while driving, it indicates fault in an exhaust gas related component
and the system is not functioning properly. Have the system checked
and serviced as soon as possible.
"MAINTENANCE REQUIRED" WARNING LIGHT (IF EQUIPPED)
Light comes on at 50,000 miles, 80,000 miles, 100,000 miles
and 120,000 miles (150,000 miles on 1990-91 models) as a service
reminder that it is time for the periodic maintenance of the emission
control system. Have the system inspected and serviced as necessary
when light comes on. Continued operation of vehicle without having
system serviced after warning light comes on may adversely affect
proper performance of the emission control system. Reset warning
light, after the system has been checked, by pushing the reset switch
in front of the combination meter. Remove the warning light bulb after
the last maintenance service at 120,000 miles (150,000 miles on 1990-
91 models).
"A/T TEMPERATURE" WARNING LIGHT (IF EQUIPPED)
Light comes on when the automatic transmission fluid
temperature becomes abnormally high. If light comes on, reduce engine
speed, stop car and put it in "P" (Park) position. Leave engine
running until light goes out. Normal vehicle operation may be resumed
after light has gone out. If light does not go out, have the system
checked and serviced as necessary.
WHEEL LOCK INDICATOR LIGHT (IF EQUIPPED)
Light comes on when automatic free-wheeling hubs are locked.
If ignition is turned off, indicator light will not come on when

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TR AN SM IS SIO N S ER VIC IN G - A /T

1991 M it s u bis h i M onte ro
1991 TRANSMISSION SERVICING
Automatic Transmission
Mitsubishi: Eclipse, Galant, Mirage,
Montero, Pickup, Precis, 3000GT
IDENTIFICATION
MITSUBISHI AUTOMATIC TRANSMISSION APPLICATIONS








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Model Transmission/Transaxle
Eclipse
1.8 & 2.0L ........................... Model F4A22 Transaxle
2.0L Turbo ........................... Model F4A33 Transaxle
All-Wheel Drive (AWD) ................ Model W4A33 Transaxle
Galant
AWD .................................. Model W4A32 Transaxle
DOHC ................................. Model F4A22 Transaxle
SOHC ........................ Model KM175 or F4A22 Transaxle
Mirage
1.5L ................................. Model F3A21 Transaxle
1.6L ................................. Model F4A21 Transaxle
Montero ............................ Model V4AW2 Transmission
Pickup ............................. Model R4AC1 Transmission
Precis ................................ Model KM176 Transaxle
3000GT ................................ Model F4A33 Transaxle









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LUBRICATION
TRANSAXLE/TRANSMISSION SERVICE INTERVALS
Check fluid level every 12 months or 15,000 miles. Change
fluid and filter every 30,000 miles. If vehicle is operated under
severe condition, change fluid more often. If severe darkening of
fluid and strong odor are noted, bands should also be adjusted (if
equipped).
TRANSFER CASE SERVICE INTERVALS
On 4WD and AWD models, change transfer case fluid every 30,
000 miles.
CHECKING FLUID LEVEL
TRANSAXLE/TRANSMISSION
1) Park vehicle on level area. Ensure oil is at normal
operating temperature, parking brake is engaged, and engine is at
idle. Move gear selector through each position, stopping briefly in
each position.
2) Place gear selector in Neutral, and clean area around
dipstick tube. Ensure fluid level is between lower and upper marks,
but never over upper mark, in HOT range. Add or drain fluid if
necessary.

fluid to bring level to lower mark of dipstick if necessary. Recheck
fluid level after transmission is at normal operating temperature.
TRANSFER CASE
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. On 3000GT, lubricant
level should be approximately .5" (13 mm) below fill hole on side of
transfer case. On all others models, lubricant level should be to
bottom of fill hole on side of transfer case.
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE CHECK (EXCEPT MONTERO & PICKUP)
1) Set parking brake. Place shift lever in Neutral position.
Attach engine tachometer. Remove line pressure port plug located above
front transaxle shaft, forward of governor pressure port plug. On
Precis, line pressure port is located below bell housing, at front of
transaxle oil pan. Using appropriate adapter, attach pressure gauge.
2) Start engine, and bring to operating temperature. With
gear selector in Drive position, bring engine speed to 2500 RPM. Pull
throttle control cable (if equipped) wide open at transaxle side.
3) Line pressure should be 98-100 psi (6.9-7.0 kg/cm
) on
Mirage, or 124-127 psi (8.7-8.9 kg/cm) on all others. If line
pressure is not to specification, proceed to LINE PRESSURE ADJUSTMENT.
LINE PRESSURE ADJUSTMENT (EXCEPT MONTERO & PICKUP)
1) Drain transaxle fluid. Remove oil pan. Disconnect throttle
control cable from throttle cam. Remove oil temperature sensor (if
equipped). Disconnect solenoid connector. On some models, it may be
necessary to push solenoid wire harness connector and grommet into
transaxle case.
2) Remove oil filter screen and plate. Noting location and
length of bolts, remove valve body. DO NOT drop internal parts. Adjust
line pressure by turning regulator valve adjusting screw.
3) Turn adjusting screw counterclockwise to increase pressure
or clockwise to decrease pressure. One complete turn of adjusting
screw changes line pressure as follows.
* 3.7 psi (.26 kg/cm
) on Mirage with F3A21 Transaxle
* 5.4 psi (.39 kg/cm) on Precis
* 54 psi (3.8 kg/cm) on all others
4) After adjustment, reverse removal procedure to install.
Refill transaxle.
LINE PRESSURE (MONTERO)
1) Remove plug from line pressure take-off port located
behind transmission shift control lever. Install Hydraulic Pressure
Meter (MD998330) with Adapter (MD998206).
2) Place vehicle on dynamometer. Apply parking brake and
start engine. With brake applied, place transmission in Drive. Note
pressure at idle. Pressure should be 74-85 psi (5.2-6.0 kg/cm
).
3) Raise engine RPM to stall speed (2100-2400 RPM). Note lin\
e
pressure. Pressure should be 156-185 psi (11.0-13.0 kg/cm
).
4) Shift transmission into Reverse with brake applied. At
idle, pressure should be 112-130 psi (7.9-9.1 kg/cm
). Raise engine
RPM to stall speed (2100-2400 RPM). Note line pressure. Pressure
should be 227-285 psi (16.0-20.0 kg/cm
). If readings are not to