1991 MITSUBISHI MONTERO service
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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
Page 1185 of 1333
\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
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 1240 of 1333
knuckles steering linkage
Rack and pinion mounting Tighten all mounting
loose bolts
Rack and pinion out of See adjustment in
adjustment STEERING article
Tie rod end loose Tighten and check
steering linkage
Excessive Pitman shaft-to- Repair as necessary
ball nut lash
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Poor Lack of lubricant in ball Lubricate and service
Returnability joint or linkage systems
Binding in linkage or ball See STEERING LINKAGE
joints and SUSPENSION article
Improper front end alignment See WHEEL ALIGNMENT
article
Improper tire pressure Inflate to proper
pressure
Tie rod binding Inflate to proper
pressure
Shaft seal rubbing shaft See STEERING COLUMN
article
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Excessive Improper tire pressure Inflate to proper
Vertical Motion pressure
Tires, wheels or rotors Balance tires then
out of balance check wheels and
rotors
Worn or faulty shock Check and replace if
absorbers necessary
Loose tie rod ends or Tighten or replace if
steering necessary
Loose or worn wheel See SUSPENSION article
bearings
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Steering Pulls Improper tire pressure Inflate to proper
to One Side pressure
Front tires are different Rotate or replace if
sizes necessary
Wheel bearings not See FRONT SUSPENSION
article
adjusted properly
Bent or broken suspension See FRONT SUSPENSION
components article
Improper wheel alignment See WHEEL ALIGNMENT
article
Page 1244 of 1333
Reaction ring sticking See POWER STEERING GEAR
in housing head article
Steering pump internal See POWER STEERING PUMP
leakage article
Steering gear-to-column See STEERING COLUMN
misalignment article
Lack of lubrication in Service front suspension
linkage
Lack of lubrication in Service front suspension
ball joints
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Increased Effort High internal pump leakage See POWER STEERING PUMP
When Turning article
Wheel Fast Power steering pump belt Adjust or replace if
Foaming, Milky slipping necessary
Power Steering
Fluid, Low Fluid Low fluid level Check and fill to
Level or Low proper level
Pressure
Engine idle speed to low Adjust to correct
setting
Air in pump fluid system See POWER STEERING PUMP
article
Pump output low See POWER STEERING PUMP
article
Steering gear See POWER STEERING GEAR
malfunctioning article
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Wheel Surges Low fluid level Check and fill to proper
or Jerks level
Loose fan belt Adjust or replace if
necessary
Insufficient pump See POWER STEERING PUMP
pressure article
Sticky flow control valve See POWER STEERING PUMP
article
Linkage hitting oil pan Replace bent components
at full turn
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Kick Back or Air in pump fluid system See POWER STEERING PUMP
Free Play article
Worn poppet valve in See POWER STEERING PUMP
steering gear article
Excessive over center See POWER STEERING GEAR
lash article
Thrust bearing out of See POWER STEERING GEAR
adjustment article
Page 1309 of 1333
subtracted by the width measured at the front of the tires at about
spindle height. A positive figure would indicate toe-in and a negative
figure would indicate toe-out. If the distance between the front and
rear of the tires is the same, toe measurement would be zero. To
adjust:
1) Measure toe-in with front wheels in straight ahead
position and steering wheel centered. To adjust toe-in, loosen clamps
and turn adjusting sleeve or adjustable end on right and left tie
rods. See Figs. 2 and 5.
2) Turn equally and in opposite directions to maintain
steering wheel in centered position. Face of tie rod end must be
parallel with machined surface of steering rod end to prevent binding.
3) When tightening clamps, make certain that clamp bolts are
positioned so there will be no interference with other parts
throughout the entire travel of linkage.
Fig. 5: Wheel Toe-In (Dimension A Less Dimension B)
TOE-OUT ON TURNS
1) Toe-out on turns (turning radius) is a check for bent or
damaged parts, and not a service adjustment. With caster, camber, and
toe-in properly adjusted, check toe-out with weight of vehicle on
wheels.
2) Use a full floating turntable under each wheel, repeating
test with each wheel positioned for right and left turns. Incorrect
toe-out generally indicates a bent steering arm. Replace arm, if
necessary, and recheck wheel alignment.
Page 1310 of 1333
STEERING AXIS INCLINATION
1) Steering axis inclination is a check for bent or damaged
parts, and not a service adjustment. Vehicle must be level and camber
should be properly adjusted. See Fig. 6.
2) If camber cannot be brought within limits and steering
axis inclination is correct, steering knuckle is bent. If camber and
steering axis inclination are both incorrect by approximately the same
amount, the upper and lower control arms are bent.
Fig. 6: Checking Steering Axis Inclination
Page 1317 of 1333
WIR IN G D IA G RAM S YM BO LS
1991 M it s u bis h i M onte ro
WIRING DIAGRAMS
How To Use The Wiring Diagrams
WIRING DIAGRAMS
INTRODUCTION
The wiring diagrams and technical service bulletins,
containing wiring diagram changes, are obtained from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
All diagrams are arranged with the front of the vehicle at
the left side of the first page and the rear of the vehicle at the
right side of the last page. Accessories are shown near the end of the
diagram.
Components are shown in their approximate location on the
vehicle. Due to the constantly increasing number of components on
vehicles today, it is impossible to show exact locations.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires, and diagrams seldom exceeded 4
pages in length. Today some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today, the majority of diagrams
now follow a much improved format, which permits space for internal
switch details and connector shapes.
Any wires that don't connect directly to their components are
identified on the diagram to indicate where they go. There is a legend
on the first page of each diagram, detailing component location. It
refers you to sub-systems, using grid NUMBERS at the top and bottom of
the page and grid LETTERS on each side. This grid system works in a
manner similar to that of a road map.
HOW TO USE THE WIRING DIAGRAMS
1) On the first page of the diagram, you will find a listing
of major electrical components or systems. Locate the specific
component or system you wish to trace. A grid number and letter will
follow the component's name.
2) Use the grid NUMBERS (arranged horizontally across the top\
and bottom of each page) to find the page of the wiring diagram that
contains the component you're seeking. When you reach this page, use
the grid LETTERS on the side of the page to determine the component's
vertical location.
3) Locate the circuit you need to service. The internals are
shown for switches and relays to assist you in understanding how the
circuit operates.
NOTE: In some of the newer wiring diagram articles in this
product, there is a Legend for the wiring diagrams that has
been created to make locating components easier. For these
articles, there will be a COMPONENT LOCATION MENU title in
the article main menu. These articles will also have the
original legend available on the first graphic.