1991 MITSUBISHI MONTERO clutch

CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION








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Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.









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CLUTCH FORKS
CLUTCH FORK INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION








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Condition Code Procedure
Cover gasket distorted .. A .... Require replacement of cover
gasket.
Cover gasket gummy ...... A .... Require replacement of cover
gasket.
Cylinder leaking fluid
from rear of bore ...... A .. Require repair or replacement.
Cylinder leaking fluid
internally ............. A ............ Require replacement.
Dust boot missing ....... C ..... Require replacement of dust
boot.
Dust boot punctured ..... A ..... Require replacement of dust
boot.
Dust boot torn .......... A ..... Require replacement of dust
boot.
Fluid level incorrect ... B . Require fluid level adjustment.
Housing damaged, affecting
performance ............ A .. Require repair or replacement.
Master cylinder has
residue in reservoir
(make parallel w/brakes
when they are done) .... 2 .......... ( 1) Further inspection
required.
Threads damaged ......... A ...... Require repair replacement
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - DO NOT replace master cylinder unless it exhibits
conditions listed for replacement. You may suggest fluid
change according to OEM service intervals.









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CLUTCH PEDALS
CLUTCH PEDAL INSPECTION








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Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .......... Require replacement of
pedal pad.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.









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CLUTCH PIVOTS
CLUTCH PIVOT INSPECTION








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Condition Code Procedure
Bent .................... A ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH PRESSURE PLATES
See PRESSURE PLATES .
CLUTCH RELEASE BEARINGS
CLUTCH RELEASE BEARING INSPECTION








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Condition Code Procedure
Collar broken ........... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Rough when rotated as an
assembly ............... B ............ Require replacement.
Seized .................. A ............ Require replacement.
Wear exceeds
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDER (CONCENTRIC) INSPECTION








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Condition Code Procedure
Bearing rough when rotated
as an assembly ......... B ............ Require replacement.
Bearing seized .......... A ............ Require replacement.
Bleeder pipe leaks ...... A .. Require repair or replacement.
Carrier assembly worn,
affecting performance .. A ........... Require replacement.
Collar broken ........... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Housing leaks ........... A ............ Require replacement.
Inoperative ............. A ............ Require replacement.
Release binding ......... A ............ Require replacement.
Spring broken ........... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION








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Condition Code Procedure
Binding ................. A .. Require repair or replacement.
Bleeder port damaged (not
repairable) ............ A ........ ( 1) Require replacement.
Bleeder port damaged
(repairable) ........... A ............. ( 1) Require repair.
Bleeder screw broken off
in slave cylinder ...... A ........ ( 1) Require replacement.
Bleeder screw seized .... A ........ ( 2) Require replacement.
Bore corroded (pitted) .. B ............ Require replacement.
Bore grooved ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 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 it has
been made.









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COMPANION FLANGES
See YOKES AND SLIP YOKES .
CONNECTORS
See WIRING HARNESSES AND CONNECTORS .
COOLER BYPASS VALVES
COOLER BYPASS VALVE INSPECTION








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Condition Code Procedure
Inoperative ............. A ............ Require replacement.
Installed incorrectly ... A ................. Require repair.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A .. Require repair or replacement.









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COOLER LINES
COOLER LINE INSPECTION








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Condition Code Procedure
Abrasion damage, affecting
structural integrity ... A .. Require repair or replacement.
Abrasion damage, not
affecting structural
integrity .............. .. ........ No service suggested or
required.
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.

performs its intended
function ............... A ............ Require replacement.
Weights missing ......... A ............ Require replacement.









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FLUID LEVEL INDICATORS
See DIP STICKS (FLUID LEVEL INDICATORS) .
FLUIDS AND LUBRICANTS
FLUID AND LUBRICANT INSPECTION








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Condition Code Procedure
Application incorrect ... B ........ ( 1) Require replacement.
At service interval ..... 3 ............ Suggest replacement.
Beyond service interval . 3 ............ Suggest replacement.
Burned .................. .. ......... ( 2) Further inspection
required.
Contaminated, for example,
fluid other than hydraulic
fluid present .......... A or B .... ( 3)( 4) Require service.
Exceeding service
interval ............... 3 ............ Suggest replacement.
Hydraulic fluid
incorrect .............. B ............ ( 5) Require service.
Level incorrect ......... B ..... Require correction of fluid
level.
Near service interval ... 3 ............ Suggest replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A ............ ( 3) Require service.
Varnished ............... .. ......... ( 6) Further inspection
required.
( 1) - Determine and correct cause.
( 2) - Fluid that is burned indicates a serious problem.
Determine and correct the cause.
( 3) - If a fluid other than hydraulic fluid is present in the
hydraulic system which DOES affect the rubber parts, the
required service is to: 1) remove all components having
rubber parts from the system, 2) flush lines with
denatured alcohol or hydraulic cleaner, 3) repair or
replace all components having rubber parts, and 4) bleed
and flush with correct hydraulic fluid. (Code A)
( 4) - If a fluid other than hydraulic fluid is present in the
hydraulic system which DOES NOT affect the rubber parts,
the required service is to flush and fill with the
correct hydraulic fluid. (Code B)
( 5) - If a fluid other than specification hydraulic fluid is
present in the hydraulic system, the required service
is to flush and fill with the correct hydraulic fluid.
( 6) - Fluid that is varnished may indicate a serious problem.
Determine and correct the cause.









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FLYWHEELS
NOTE: Clutch disc replacement does not necessitate flywheel
reconditioning, unless other conditions justify the
reason to do so.

incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.









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TORQUE CONVERTERS
TORQUE CONVERTER INSPECTION








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Condition Code Procedure
Converter clutch lock-up
operation is faulty .... A ............ Require replacement.
Cover shell damaged,
affecting performance .. A ............ Require replacement.
Does not meet stall speed
specification .......... B ............ Require replacement.
End play exceeds
specifications ......... B ............ Require replacement.
Hub broken .............. A ............ Require replacement.
Hub cracked ............. A ............ Require replacement.
Internal component
failure ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Pilot broken ............ A ............ Require replacement.
Pilot worn, affecting
performance ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Weights missing ......... C ............ Require replacement.









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TRANSAXLE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSDUCERS (TRANSMISSION)
See SENSORS.
TRANSMISSION COOLERS
TRANSMISSION COOLER INSPECTION








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Condition Code Procedure
Air flow obstruction .... A ................. Require repair.
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.
Connection leaking ...... A .. Require repair or replacement.
Contaminated ............ A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting

A/T Thermoswitch On thermostat housing.
Brakelight Switch On bracket, above brake pedal.
Clutch Switch On bracket, above brake pedal.
Coolant Temperature Switch On front of intake manifold.

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* E LE C TR IC AL S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM)
AIR BAGS
ALTERNATORS AND GENERATORS
AMPLIFIERS
ANTENNAS
BATTERIES
BATTERY CABLES
BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS
CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES
CIRCUIT BREAKERS
CLUTCH SWITCHES
CONNECTORS
CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES
CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS
DEFROSTERS
DELAYS
DIMMERS
ELECTRIC HEATERS
EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GAUGES
GENERATORS
GROUND CABLES AND STRAPS
GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS)
HORNS AND SIRENS