1991 MITSUBISHI MONTERO Service Manual

of caliper.
Piston sticking ......... A ........... Require rebuilding or
replacement of caliper.
Slide mechanism
sticking ............... A ... Require repair or replacement
of slide mechanism.
(1) - Only required if the hydraulic system must be opened.
( 2) - Seized is defined as a bleeder screw that cannot be
removed after a practical attempt at removing. Only
required if the hydraulic system must be opened.









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CONTROLLERS
See ELECTRONIC CONTROLLERS .
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)
DIGITAL RATIO AXLE CONTROLLER AND BUFFER INSPECTION








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Condition Code Procedure
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........ ( 1) Require replacement.
Connector missing ....... C ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . B .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. ( 2) Require repair
or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to replacement of part.
( 2) - Determine cause and correct prior to repair or
replacement of part.









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DISABLE SWITCHES
See SWITCHES.
DRUMS
Determine the need to recondition based upon individual drum
conditions that follow. Friction material replacement does not require
drum reconditioning unless other justifications exist. DO NOT
recondition new drums unless they are being pressed or bolted onto an
existing hub. It is not necessary to replace drums in axle sets.
However, when replacing or reconditioning a drum due to the conditions
that follow, you may suggest reconditioning of the other drum on the

same axle to eliminate uneven braking behavior. Always wash drums
after servicing or before installing.
DRUM INSPECTION









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Condition Code Procedure
Balance weight missing .. .. ........ No service suggested or
required.
Bell-mouthed, affecting
performance ............ A ....... Require reconditioning or
replacement.
Cooling fin broken ...... .. ........ No service suggested or
required.
Cracked ................. B ............ Require replacement.
Drum diameter is greater
than OEM "machine to"
specifications but less
than "discard at"
specifications, and the
drum does not require
reconditioning ......... 1 ........ (1) Suggest replacement.
Drum diameter will exceed
OEM "machine to"
specifications after
required
reconditioning ......... B ........ ( 2) Require replacement.
Hard-spotted ............ 2 ....... Suggest reconditioning or
replacement.
Measured diameter is
greater than OEM discard
specifications ......... B ............ Require replacement.
Out-of-round (runout),
affecting performance .. A ....... Require reconditioning or
replacement.
Out-of-round (runout),
exceeding manufacturer's
specifications ......... B ....... Require reconditioning or
replacement.
Scored .................. B ....... Require reconditioning or
replacement.
Surface threaded due to
improper machining ..... B ....... Require reconditioning or
replacement.
Tapered, affecting
performance ............ A ....... Require reconditioning or
replacement.
( 1) - Only applies to vehicles for which OEM "machine to"
specifications exist. If OEM does not supply "machine to"
specifications, the drum may be worn to discard
specifications.
( 2) - If OEM does not supply "machine to" specifications, you
may machine to discard specifications.









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ELECTRICAL PUMPS AND MOTORS
Copied fuel pump conditions from engine UIGs & deleted
pulsator from leaking conditions.
ELECTRICAL PUMP AND MOTOR INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A .............. (1) Require repair
or replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........ ( 2) Require replacement.
Inoperative ............. A .............. ( 3) Require repair
or replacement.
Leaking externally ...... A .. Require repair or replacement.
Leaking internally ...... A .. Require repair or replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. ( 1) Require repair
or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or replacement
of part.
( 2) - Determine source of contamination. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of OEM
specifications.









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ELECTRONIC CONTROLLERS
ELECTRONIC CONTROLLER INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
missing ................ C .......... Require replacement of

hardware.
Attaching hardware threads
damaged ................ A ... Require repair or replacement
of hardware.
Attaching hardware threads
stripped (threads
missing) ............... A ... Require repair or replacement
of hardware.
Code set (if
applicable) ............ A .......... (1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A .. Require repair or replacement.
Inoperative ............. B .. Require repair or replacement.
( 3) Further inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Refer to manufacturer's diagnostic trouble code procedure
and require repair or replacement of affected component(s).
( 2) - Determine cause and correct prior to repair or replacement
of part.
( 3) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable. Check
for accepted cleaning procedure.









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FLUID
See BRAKE FLUID.
FLUID LEVEL SENSOR SWITCHES
See SWITCHES.
FOUR WHEEL DRIVE SWITCHES
See SWITCHES.

FRICTION MATERIAL
NOTE: Original Equipment Manufacturer (OEM) specifications
designate replacement at different thicknesses.
CAUTION: It is required that friction material be matched in axle
sets for consistent braking characteristics.
FRICTION MATERIAL INSPECTION









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Condition Code Procedure
Contaminated, for example,
fluid that leaked from
caliper, wheel cylinder,
or axle seal ........... A ........ ( 1) Require replacement.
Cracked through ......... B Require replacement.
Flaking or chunking ..... B Require replacement.
Glazed (shiny) .......... .. ........ No service suggested or
required.
Grooves or ridges ....... .. .... ( 2) No service suggested or
required.
Permanently attached
hardware bent .......... A ............ Require replacement.
Permanently attached
hardware broken ........ A ............ Require replacement.
Permanently attached
hardware loose ......... A ............ Require replacement.
Permanently attached
hardware missing ....... C ............ Require replacement.
Permanently attached
hardware seized ........ A .. Require repair or replacement.
Rivets loose ............ B ............ Require replacement.
Separating from backing . B ............ Require replacement.
Shoe table or web bent .. B ............ Require replacement.
Shoe table or web
cracked ................ A ............ Require replacement.
Shoe table or web worn,
affecting performance .. A ............ Require replacement.
Surface cracking ........ .. ........ No service suggested or
required. Further inspection
may be necessary to determine
cause.
Tapered wear ............ B ........ ( 3) Suggest replacement.
Thickness of one pad is
greater than opposite pad
in the same caliper
(uneven wear) .......... .. .... ( 4) Replacement of friction
material not suggested or
required. Further inspection
required. See CALIPERS
and CALIPER HARDWARE.
Wear indicator device
(electronic) contacts
rotor .................. B ...... ( 5) Require replacement of
appropriate parts.
Wear indicator device
(mechanical) bent ....... .. .......... ( 6) Further inspection
required.
Wear indicator device
(mechanical) broken .... .. ......... ( 6) Further inspection
required.

Wear indicator device
(mechanical) contacts
rotor .................. .. ......... (6) Further inspection
required.
Worn close to minimum
specifications ......... 1 ........ ( 7) Suggest replacement.
Worn to, or below minimum
specifications ......... B ............ Require replacement.
( 1) - Identify and repair cause of contamination prior to
replacing friction material.
( 2) - When reconditioning or replacing drums or rotors,
replacement of friction material may be suggested
depending on the severity of the grooves or ridges.
( 3) - Some vehicles use pads that are tapered by design. Refer
to specific vehicle application. If not normal, require
replacement of pads and correction of cause.
( 4) - Uneven pad thickness is normal on some vehicles. Refer to
specific vehicle applications.
( 5) - The pad wear indicator light may come on due to other
electrical problems.
( 6) - Explain to the customer that the purpose of the wear
indicator is to alert him or her to check for friction
wear. Wear indicators may be bent or broken. Therefore,
the friction material must be measured. The need for
friction material replacement is determined based upon
the conditions stated in this section. Periodic inspection
is suggested.
( 7) - When the part appears to be close to the end of its useful
life, replacement may be suggested.









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G SENSORS
See ACCELEROMETERS .
HOSES
HOSE INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............. A ... Require repair or replacement
of hardware.
Blistered ............... B ............ Require replacement.
Fitting threads damaged . A .. Require repair or replacement.
Fitting threads stripped
(threads missing) ...... A ............ Require replacement.
Incorrectly secured ..... B ................. Require repair.
Inner fabric
(webbing) cut .......... B ............ Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Outer covering is cracked
to the extent that
inner fabric of hose

is visible ............. B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ................. Require repair.









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HYDRAULIC MODULATORS
NOTE: Many modulators can only be replaced as complete
assemblies. Whenever possible, replace the failed
component part. If replacement of the failed part is not
possible, then replace the modulator assembly.
HYDRAULIC MODULATOR INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........ ( 1) Require replacement.
Connector missing ....... C ............ Require replacement.
Disabled ................ A .. Require repair or replacement.
Electrical failure ...... A .. Require repair or replacement.
External leak ........... A .. Require repair or replacement.
Housing cracked ......... B .. Require repair or replacement.
Inoperative ( 2) ......... A .. Require repair or replacement.
Internal leak ........... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Valve stuck ............. A .. Require repair or replacement.
Wire lead burned ........ A .. Require repair or replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to replacement of part.
( 2) - Inoperative includes intermittent operation or out of OEM
specification.

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HYDRO-BOOSTERS
NOTE: Hydro-boosters and hydro-electric boosters are combined.
HYDRO-BOOSTER INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........ ( 1) Require replacement.
Connector missing ....... C ............ Require replacement.
Does not apply assist, or
inadequate assist ...... A .. Require repair or replacement.
Leaking ................. B .. Require repair or replacement.
Leaks fluid at fitting .. B ........... Require tightening or
replacement.
Leaks fluid at unit ..... B .. Require repair or replacement.
Leaks fluid from pressure
hose(s) ................ B . Require replacement of hose(s).
Leaks fluid into passenger
compartment ............ B .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Determine cause and correct prior to replacement of part.









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HYDRO-ELECTRIC BOOSTERS (POWERMASTER)
See HYDRO-BOOSTERS .
IGNITION DISABLE SWITCHES
See SWITCHES.