1991 MITSUBISHI MONTERO lock

4WD shift rail snap ring.
6) Assemble front output shaft assembly, chain and 2WD-4WD
synchronizer assembly. Align match marks made during disassembly. Link
chain tightly onto 2WD-4WD synchronizer and front output shaft
sprockets. Install both sprockets and chain to transfer case at same
time, while keeping them as far apart as possible.
7) Install center differential case assembly, rear output
shaft assembly needle bearings and rear output shaft assembly. Install
interlock plunger so it does not interfere with 2WD-4WD shift rail.
Evenly apply sealant to chain cover and install chain cover.
8) Install high-low shift rail through high-low shift rail
hole into shift fork. Align spring pin holes in high-low shift rail
and shift fork. Tap in spring pin so slit is facing shift rail shaft
center. Install and tighten high-low shift rail plug to specification.
See TORQUE SPECIFICATIONS .
9) Before installing front output shaft cover, measure
protrusion "A" of front output shaft rear bearing and recess "B" of
cover and calculate clearance. See Fig. 11. If clearance is greater
than .079" (2.00 mm), select and install spacer to bring clearance
within specification. If clearance is less than .079" (2.00 mm), use
wave spring alone. Apply sealant to both sides of gasket and install
gasket and cover. Apply Locking Adhesive (3M 4170 Stud Lock) to bolts
and tighten to specification. See TORQUE SPECIFICATIONS.
Fig. 11: Measuring Rear Output Shaft Bearing Clearance (Montero)
Courtesy of Mitsubishi Motor Sales of America.
10) Install rear output shaft ball bearing snap ring. Measure
clearance between chain cover and snap ring. Add .0008-.0039" (.02-.10

TORQUE SPECIFICATIONS TABLE








\









\









\









\









\









\






Application Ft. Lbs. (N.m)
Adapter-To-Transfer Bearing Retainer ......... (1) 14 (19)
Case Nuts & Bolts .......................... 22-31 (30-42)
Center Differential Case Bolts ................... 48 (65)
Chain Cover Bolt ........................... 22-31 (30-42)
Detection Switch ............................. ( 1) 27 (36)
Drain Plug ................................. 22-26 (30-35)
Dynamic Damper ................................... 52 (70)
High-Low Shift Rail Plug ..................... ( 1) 24 (33)
Interlock Plunger Plug ................. ( 1) 22-26 (30-35)
Lock Plate Bolts ........................... 11-16 (15-22)
Oil Dam Cover ................................ ( 1) 14 (19)
Oil Filler Plug ............................ 22-26 (30-35)
Output Shaft Cover Bolt .................... 11-16 (15-22)
Poppet Plug .................................. ( 1) 27 (36)
Pulse Rotor Bolt ....................... ( 2) 11-16 (15-22)
Rear Cover Bolt ............................ 11-16 (15-22)
Rear Output Shaft Lock Nut ............... 74-96 (100-130)
Seal Plug .............................. ( 2) 22-31 (30-42)
Speedometer Sleeve Clamp Bolt .............. 11-16 (15-22)
4WD Indicator Light Switch ................... ( 2) 22 (33)
INCH Lbs. (N.m)
Pulse Generator Bolt .................. ( 2) 89-106 (10-12)
Side Cover Bolt ............................. 71-89 (8-10)
( 1) - Montero.
( 2) - Ram-50.









\









\









\









\









\









\






WIRING DIAGRAMS

Fig. 13: Rear Differential Lock Circuit (Montero)

REMOVAL
1) Disconnect negative battery cable. Remove front exhaust
pipe. On Montero, remove transfer case shift lever knob, dust boot and
retainer plate or console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
and remove. Disconnect all external solenoid and switch connections.
3) Disconnect speedometer cable and control cables at
transmission. Remove starter and bellhousing cover. Place reference
mark on torque converter and drive plate for reassembly reference.
Remove torque converter bolts.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
INSTALLATION
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Tighten mount bolts with weight of engine and transmission on mounts.
Ensure reference marks on drive shaft(s) and torque converter-to-drive\
plate align.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. Adjust all control cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








\









\









\









\









\









\









\


Applications Ft. Lbs. (N.m)
FWD Models
Torque Converter-To-Drive Plate Bolt
Precis ....................................... 53-55 (72-76)
All Others ................................... 34-38 (46-52)
Transaxle-To-Engine Block Bolt
Mirage
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
12-mm Bolt ................................. 31-40 (42-54)
Eclipse & Galant
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
Precis
8-mm Bolt .................................. 22-25 (30-34)
10-mm Bolt ................................. 31-40 (42-54)
3000GT
Upper Coupling Bolts ............................. 54 (73)
Lower Coupling Bolts ............................. 65 (88)

RWD Models
Torque Converter-To-Drive Plate Bolt
Montero ...................................... 25-30 (34-41)
Pickup ....................................... 33-38 (45-52)
Transmission-To-Engine Block Bolt
Montero
10x40-mm Bolt .............................. 22-30 (30-41)
12x40-mm Bolt .............................. 47-61 (64-83)
12x55-mm Bolt .............................. 58-72 (79-98)
Pickup
10x16-mm Bolt .............................. 22-30 (30-41)
10x50-mm Bolt .............................. 31-40 (42-54)
10x70-mm Bolt .............................. 31-40 (42-54)
(1) - Tighten to 84-108 INCH lbs. (10-12 N.m).









\









\









\









\









\









\









\

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

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

adjusting screw turns freely in lever.
2) Using torque wrench, tighten band adjusting screw to 30
INCH lbs. (3.5 N.m). Back off adjusting screw 6 turns. Hold adjusting
screw in this position, and tighten lock nut to 25 ft. lbs. (34 N.m).
3) Reinstall oil pan using new gasket. Tighten pan bolts to
150 INCH lbs. (17 N.m). Refill with specified transmission fluid.
KICKDOWN SERVO
ECLIPSE, GALANT, MIRAGE, PRECIS & 3000GT
1) Remove all dirt and grease around kickdown servo switch.
Remove snap ring and kickdown servo switch.
2) To prevent servo piston from turning, install Adapter
(MD998915) and Kickdown Servo Wrench (MD998914) so tab of wrench
engages with notch of piston. See Fig. 2.
CAUTION: DO NOT push servo piston inward while installing adapter
and servo wrench. Install adapter in brake pressure port by
hand ONLY. DO NOT use wrench to tighten adapter.
Fig. 2: Adjusting Kickdown Servo (Except Montero & Pickup)
Courtesy of Mitsubishi Motor Sales of America.
3) Loosen lock nut to "V" channel of adjuster rod. See
Fig. 2 . Tighten inner section of Kickdown Service Adjustment Assembly
(MD998916) until it contacts lock nut.
4) Install outer section of kickdown service adjustment
assembly on lock nut. Rotate outer section to left and inner section
to right to contact lock nut with inner section.
5) Using an INCH lb. torque wrench on inner section, tighten
inner section to 86 INCH lbs. (9.8 N.m), and then loosen inner
section. Tighten inner section to 43 INCH lbs. (4.9 N.m).
CAUTION: Before tightening lock nut with torque wrench, tighten it
by hand until it contacts piston. If torque wrench is used