1991 MITSUBISHI MONTERO differential
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Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ........... SAE 90, 85W-90, 80W-90
API GL-5
Maximum Temperature
Less Than -30
F (-34
C) .................... SAE 75W API GL-5
Power Steering Fluid ............................. Dexron-II ATF
Rear Axle (With Limited
Slip Differential) ............ Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic ...................................... Dexron-II ATF
Manual Transaxle &
Transfer Case (4WD) ................. SAE 75W-85W, 75W-90 API
GL-4 Or GL-5
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
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Fluid Capacities
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Application Quantity
Automatic Transmission
1987-93 ...................................... 7.6 Qts. (7.2L)
1994 (3.0L SOHC) ............................. 7.6 Qts. (7.2L) \
1994 (3.0L DOHC & 3.5L) ...................... 9.0 Qts. (8.5L) \
1995 ......................................... 7.9 Qts. (7.5L)
Cooling System
1987-88 ...................................... 8.5 Qts. (8.0L)
1989-95
2.6L ........................................ 9.7 Qts. (9.2L)
3.0L ....................................... 10.0 Qts. (9.5L)
1994-95
3.5L ....................................... 10.0 Qts. (9.5L)
Differential
1987-88 ...................................... 1.9 Qts. (1.8L)
1989-94
2.6L ........................................ 1.9 Qts. (1.8L)
3.0L ........................................ 2.7 Qts. (2.6L)
1994
3.5L ........................................ 2.7 Qts. (2.6L)
1995
3.0L ........................................ 2.7 Qts. (2.6L)
3.5L ........................................ 3.3 Qts. (3.2L)
Engine Oil
1987 ......................................... 5.2 Qts. (5.0L)
1988 ......................................... 5.0 Qts. (4.8L)
1989-92 ...................................... 5.5 Qts. (5.3L)
1993-95 ...................................... 5.2 Qts. (4.9L)
Manual Transmission
1987-91 ...................................... 2.3 Qts. (2.2L)
1992 ......................................... 2.4 Qts. (2.3L)
1993-95 ...................................... 2.6 Qts. (2.5L)
Transfer Case
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![MITSUBISHI MONTERO 1991 Service Manual 1987-91 ...................................... 2.3 Qts. (2.2L)
1992-95 ...................................... 2.4 Qts. (2.3L)
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\](/manual-img/19/57332/w960_57332-724.png "MITSUBISHI MONTERO 1991 Service Manual 1987-91 ...................................... 2.3 Qts. (2.2L)
1992-95 ...................................... 2.4 Qts. (2.3L)
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1987-91 ...................................... 2.3 Qts. (2.2L)
1992-95 ...................................... 2.4 Qts. (2.3L)
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Service Labor Times
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Application Hours
30,000 (60,000) 50,000
Application Mile Service Mile Service
2.6L 4-Cylinder
Automatic Transmission .... 7.9 (8.9) ................. 2.6
Manual Transmission ....... 6.9 (7.9) ................. 2.6
3.0L V6
Automatic Transmission .... 6.1 (10.6) ................ 2.6
Manual Transmission ....... 5.1 (9.6) ................. 2.6
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LUBRICATION SPECIFICATIONS TABLE\
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Application Fluid Specifications
Brake & Clutch Fluid ........................... DOT 3 Or DOT 4
Engine Coolant ............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ..... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) .. SAE 10W-30 Or 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) ......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ..... SAE 85W-90, 80W-90 API GL-5
Maximum Temperature
Less Than -30
F (-34
C) ................... SAE 75W API GL-5
Power Steering Fluid ........................... Dexron-IIE ATF
Rear Axle (With Limited
Slip Differential) ........... Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic .................................... Dexron-IIE ATF
Manual Transaxle &
Transfer Case (4WD) ........... SAE 75W-85W, 75W-90 API GL-5
( 1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
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FLUID CAPACITIES
FLUID CAPACITIES TABLE\
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Application Quantity
A/C System R-12 Refrigerant
1983-87 .......................................... 24-26 Ozs.
1988-91 ............................................. 32 Ozs.
1992-93 ............................................. 28 Ozs.
A/C System R-134a Refrigerant ( 1)
1994-95 .......................................... 21-23 Ozs.
Automatic Transmission
Page 726 of 1333
1984-86 ................................. (2) 7.2 Qts. (6.8L)
1987-93 ..................................... 7.6 Qts. (7.2L)
1994 (3.0L SOHC) ............................ 7.6 Qts. (7.2L)
1994 (3.0L DOHC & 3.5L) ..................... 9.0 Qts. (8.5L)
1995 ........................................ 7.9 Qts. (7.5L)
Cooling System
1983-88 ..................................... 8.5 Qts. (8.0L)
1989-95
2.6L ....................................... 9.7 Qts. (9.2L)
3.0L ...................................... 10.0 Qts. (9.5L)
1994
95
3.5L ...................................... 10.0 Qts. (9.5L)
Differential
1983-88 ..................................... 1.9 Qts. (1.8L)
1989-93
2.6L ....................................... 1.9 Qts. (1.8L)
3.0L ....................................... 2.7 Qts. (2.6L)
1994
3.0L & 3.5L ................................ 2.7 Qts. (2.6L)
1995
3.0L ....................................... 2.7 Qts. (2.6L)
3.5L ....................................... 3.3 Qts. (3.2L)
Engine Oil
1983-86 ..................................... 6.0 Qts. (5.8L)
1987 ........................................ 5.2 Qts. (5.0L)
1988 ........................................ 5.0 Qts. (4.8L)
1989-91 ..................................... 5.5 Qts. (5.3L)
1992-95 ..................................... 5.2 Qts. (4.9L)
Power Steering ................................ 1.1 Qts. (1.0L)
Fuel Tank
1983-88 .................................... 15.9 Gals. (60L)
1989-90
2.6L 2-Door ............................... 15.9 Gals. (60L)
3.0L 2-Door ............................... 19.9 Gals. (75L)
2.6L & 3.0L 4-Door .......................... 24 Gals. (92L)
1991-95 ...................................... 24 Gals. (92L)
Manual Transmission
1983-91 ..................................... 2.3 Qts. (2.2L)
1992 ........................................ 2.4 Qts. (2.3L)
1993-95 ..................................... 2.6 Qts. (2.5L)
Transfer Case
1983-91 ..................................... 2.3 Qts. (2.2L)
1992-95 ..................................... 2.4 Qts. (2.3L)
( 1) - Use of R12 in a R134a system will result in SEVERE DAMAGE.
( 2) - 1983 model equipped with manual transmission only.
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Page 735 of 1333
![MITSUBISHI MONTERO 1991 Service Manual 1.8L ............................................ 6.6 Qts. (6.2L)\
2.0L ............................................ 7.6 Qts. (7.2L)\
Galant ...........................................](/manual-img/19/57332/w960_57332-734.png "MITSUBISHI MONTERO 1991 Service Manual 1.8L ............................................ 6.6 Qts. (6.2L)\
2.0L ............................................ 7.6 Qts. (7.2L)\
Galant ...........................................")
1.8L ............................................ 6.6 Qts. (6.2L)\
2.0L ............................................ 7.6 Qts. (7.2L)\
Galant ........................................... 7.6 Qts. (7.2L)\
Montero ......................................... 10.0 Qts. (9.5L)\
Pickup (2WD)
Automatic Transmission ......................... 6.4 Qts. (6.1L)\
Manual Transmission ............................ 6.3 Qts. (6.0L)\
Pickup (4WD) ..................................... 8.9 Qts. (8.4L\
)
Ram-50 (2WD)
Automatic Transmission ......................... 6.5 Qts. (6.1L)\
Manual Transmission ............................ 6.3 Qts. (6.0L)\
Ram-50 (4WD)
2.4L
Automatic Transmission ....................... 6.5 Qts. (6.1L)\
Manual Transmission .......................... 6.6 Qts. (6.2L)\
3.0L
Automatic Transmission ....................... 8.8 Qts. (8.3L)\
Manual Transmission .......................... 8.9 Qts. (8.4L)\
Stealth & 3000GT ................................. 8.8 Qts. (8.3L)\
Crankcase (Includes Filter)
Colt, Colt 200, Mirage & Summit .................. 4.2 Qts. (4.0L)\
Colt Vista ....................................... 4.0 Qts. (3.8L)\
Eclipse ...................................... (1) 4.5 Qts. (4.3L)
Galant
2.0L (SOHC) .................................... 4.0 Qts. (3.8L\
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2.0L (DOHC) ................................ ( 1) 4.5 Qts. (4.3L)
Montero .......................................... 5.5 Qts. (5.3L)\
Pickup ........................................... 4.5 Qts. (4.3L)\
Ram-50 ........................................... 5.5 Qts. (5.3L)\
Stealth & 3000GT ............................. ( 1) 4.5 Qts. (4.3L)
Differential (SAE 80W-90/API GL-5)
Colt Vista (4WD), Eclipse ........................ 1.5 Pts. (.7L\
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Galant, Stealth & 3000GT .......................... 1.5 Pts. (.7L)\
Montero
Front .......................................... 1.2 Qts. (1.1L)\
Rear ........................................... 2.7 Qts. (2.6L)\
Pickup & Ram-50
Front
2.4L ......................................... 1.6 Qts. (1.5L)\
3.0L ......................................... 2.7 Qts. (2.6L)\
Rear
2WD .......................................... 1.6 Qts. (1.5L)\
4WD
2.4L ....................................... 1.6 Qts. (1.5L)\
3.0L ....................................... 2.7 Qts. (2.6L)\
Manual Transaxle (SAE 75W-85/API GL-4)
Colt, Colt 200, Mirage & Summit
4-Speed ........................................ 3.6 Pts. (1.7L)\
5-Speed ........................................ 3.8 Pts. (1.8L)\
Colt Vista
2WD ............................................ 2.6 Qts. (2.5L)\
4WD ............................................ 2.2 Qts. (2.1L)\
Eclipse (FWD)
Except Turbo ................................... 1.9 Qts. (1.8L)\
Turbo .......................................... 2.3 Qts. (2.2L)\
Eclipse & Galant (AWD) ........................... 2.4 Qts. (2.3L\
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Galant ........................................... 1.9 Qts. (1.8L)\
Stealth & 3000GT ................................. 2.4 Qts. (2.3L)\
Manual Transmission (SAE 75W-85/API GL-4)
Montero .......................................... 2.3 Qts. (2.2L)\
Pickup & Ram-50
2WD ............................................ 2.4 Qts. (2.3L)\
4WD ............................................ 2.3 Qts. (2.2L)\
Page 765 of 1333
\003
SU SPEN SIO N - F R O NT ( 4 W D)
1 991 M it s u bis h i M onte ro
1990-92 SUSPENSION
Front - 4WD Trucks
Chrysler Motors; Ram-50
Mitsubishi; Montero, Pickup
DESCRIPTION
The independent front suspension uses upper and lower control
arm and torsion bar construction. The components used with this system
are upper control arm, lower control arm, torsion bar, shock absorber,
stabilizer bar, steering knuckle, drive shaft and front differential.
See Fig. 1 .
Fig. 1: Replacing Upper Ball Joint (Montero)
Courtesy of Mitsubishi Motor Sales of America.
BALL JOINT CHECKING
Page 768 of 1333
1) Using Socket (MB990954) and torque wrench, rotate front
hub and tighten lock nut to 95-145 ft. lbs. (129-197 N.m) to seat
bearings. Loosen nut. Retighten nut to 18 ft. lbs. (24 N.m) and loosen\
30-40 degrees.
2) Using spring scale attached to wheel stud, measure and
record turning resistance required to rotate hub/rotor assembly before
installing locking hub.
3) Apply semi-drying sealant on locking hub assembly-to-
hub/rotor contact areas. DO NOT apply sealant on outer areas of
hub/rotor assembly, toward brake contact areas.
4) Align locking hub assembly key area with steering knuckle
keyway area. Loosely install locking hub assembly on hub/rotor
assembly. Ensure locking hub assembly fully contacts hub/rotor
assembly.
5) Install locking hub retaining bolts. Tighten to
specification. See TORQUE SPECIFICATIONS table at end of article.
Using spring scale attached to wheel stud, measure turning resistance
required to rotate hub/rotor assembly.
6) Subtract turning resistance measured in step 2) (before
installing locking hub) from turning resistance measured in step 5)
(after installing locking hub). If difference exceeds 3.1 lbs. (14 N)\
,
check for incorrect installation of locking hub assembly or
components.
7) Install shim and snap ring on drive axle. Rotate drive
axle until maximum end play is obtained. Using dial indicator, check
drive axle end play.
8) Drive axle end play should be .008-.020" (.20-.51 mm). If\
end play is not within specification, adjust drive axle end play by
changing axle shaft shim. Install new "O" ring and cover. Tighten
cover to specification. See TORQUE SPECIFICATIONS table at end of
article.
LOWER CONTROL ARM R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
front skid plate and undercover (if equipped). Remove torsion bar. See\
TORSION BAR under REMOVAL & INSTALLATION. Remove stabilizer bar bolt
from control arm.
2) Remove shock absorber-to-control arm bolts. Loosen but DO
NOT remove lower ball joint-to-steering knuckle nut. Using ball joint
fork, separate lower ball joint from steering knuckle.
3) Remove ball joint stud nut from steering knuckle. Remove
control arm shaft. See Fig. 1. Remove torque arm. Remove lower control
arm pivot bolt. Remove lower control arm.
INSPECTION
1) Inspect control arm for cracks or deformation. Check ball
joints. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION.
2) Inspect ball joint dust covers for damage. Replace dust
covers if damaged. Inspect control arm bushing and frame bracket
bushing for damage. Replace if necessary.
3) If frame bracket bushing needs replacing, install Bushing
Remover/Installer (MB990958-01) in bushing. See Fig. 3. Tighten
bushing remover/installer bolt until bushing is removed. Reverse
bushing remover/installer to install bushing.
NOTE: Differential carrier may require relocation to replace left
bracket bushing.
Page 1151 of 1333
TR AN SFE R C ASE
1991 M it s u bis h i M onte ro
1991-94 TRANSFER CASES
Mitsubishi
Dodge; Ram-50
Mitsubishi; Pickup, Montero
APPLICATION
TRANSFER CASE APPLICATIONS TABLE \
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Application ( 1) Transmission Model
Dodge
1991-93 Ram-50 (2.4L) .......................... V5M21-1
1991-93 Ram-50 (3.0L M/T) ...................... V5MT1-2
1991-93 Ram-50 (3.0L A/T) ...................... V4AC1-2
Mitsubishi
1991-92 Pickup ................................. V5MT1-2
1991 Montero (M/T) ............................. V5MT1-2
1991 Montero (A/T) ............................. V4AW2-2
1992 Montero (M/T) ......................... ( 2) V5MT1-3
1992 Montero (A/T) ......................... ( 2) V4AW2-3
1993-94 Montero (M/T) ...................... ( 2) V5MT1-2
1993-94 Montero (A/T) ........................ ( 2) R4AC1
( 1) - Transfer case is indicated by a -2 or -3 following the
transmission model number.
( 2) - Transfer cases for Montero are identical for automatic and
manual transmission models.
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DESCRIPTION
Transfer case is a part-time, 2-speed unit with a 3-piece
aluminum case. Transfer case has a floor-mounted shifter and integral
speedometer gear. In Montero a Viscous Coupling Unit (VCU) and center
differential allows 2WD-to-4WD shifting at speeds under 62 MPH and
full-time 4WD operation.
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See the
COMPUTER RELEARN PROCEDURES article in the GENERAL
INFORMATION section.
TESTING
4WD INDICATOR CONTROL UNIT (MONTERO)
The 4WD indicator control unit is located behind radio or CD
player. Remove 4WD indicator control unit and disconnect harness.
Backprobe harness connector and measure voltage between terminal No. 8
(ground) and each respective terminal. Compare test results with
chart. See Fig. 1.
DETECTION SWITCH
Page 1152 of 1333
NOTE: With switch removed, check continuity between switch
connector terminal and switch body. With switch installed,
check continuity between switch connector terminal and
transfer case.
4WD Indicator Light Switch (RAM-50)
With switch removed, check continuity between connector
terminal and switch body. With switch end pressed, there should be no
continuity. With switch end released, there should be continuity.
Center Differential Lock Operation Detection Switch (Montero)
Check continuity between terminals at Brown wire connector
terminal on top of transfer case. With transfer control lever in "4H"
position, there should be no continuity. With transfer control lever
in "4HLc" position, there should be continuity. See Fig. 2.
4WD Operation Detection Switch (Montero)
Check continuity between terminals at Black wire connector
terminal on top of transfer case. With transfer control lever in "2H"
position, there should be no continuity. With transfer control lever
in "4H" position, there should be continuity. See Fig. 2.
Center Differential Lock Detection Switch (Montero)
Check continuity between terminals at Brown wire connector
terminal on side of transfer case. With transfer control lever in "4H"
position, there should be no continuity. With transfer control lever
in "4HLc" position, there should be continuity. See Fig. 2.
2WD-4WD Detection Switch (Montero)
Check continuity between terminals at Black wire connector
terminal on side of transfer case. With transfer control lever in "4H"
position, there should be no continuity. With transfer control lever
in "2H" position, there should be continuity. See Fig. 2.
HI/LO Detection Switch (Montero)
Check continuity between terminals at White wire connector
terminal on side of transfer case. With transfer control lever in "N"
(between "4HLc" and "4LLc") position, there should be no continuity.
With transfer control lever in "4HLc" position, there should be
continuity. With transfer control lever in "4LLc" position, there
should be continuity. See Fig. 2.