1991 MITSUBISHI MONTERO steering

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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

LOWER BALL JOINT
Place ball joint in soft-jawed vise. Install dial indicator,
with stem resting on end of ball joint stud. Measure ball joint stud
end play. Replace ball joint if end play exceeds .02" (.5 mm).
UPPER BALL JOINT
1) With ball joint disconnected from steering knuckle, place
nut on ball joint stud. Using INCH lb. torque wrench, measure starting
torque required to rotate ball joint stud.
2) Starting torque must be 7-30 INCH lbs. (.8-3.4 N.m). If
starting torque is not within specification, replace ball joint
(Montero) or upper arm (Ram-50 and Pickup). For ball joint replaceme\
nt
on Montero, see UPPER BALL JOINT under REMOVAL & INSTALLATION.
WHEEL BEARINGS ADJUST
PRELOAD
1) Remove locking hub assembly. See LOCKING HUB under REMOVAL
& INSTALLATION. Remove lock washer-to-lock nut bolts and lock washer.
Remove brake caliper to ensure brake pads are not contacting rotor.
2) Using Socket (MB990954-01) and torque wrench, rotate fron\
t
hub and tighten lock nut to 95-145 ft. lbs. (129-197 N.m) to seat
bearings. Loosen nut.
3) Retighten nut to 18 ft. lbs. (24 N.m) and loosen 30-40
degrees. After setting preload, check hub turning resistance and axial
play.
HUB TURNING RESISTANCE & AXIAL PLAY
1) Using INCH lb. torque wrench or spring scale attached to
wheel stud, measure hub turning resistance. Turning resistance should
be 1-4 lbs. (.45-1.8 kg) if measured with spring scale or 2.6-11.3
INCH lbs. (.3-1.3 N.m) if measured with torque wrench.
2) Using dial indicator, check front hub axial play. Axial
play should be .002" (.05 mm) or less. Adjust wheel bearing so turning\
resistance and axial play are within specification. If turning
resistance and axial play cannot be adjusted to specifications, check
wheel bearing condition and installation. Install lock washer.
3) If lock washer and lock nut holes are not aligned, align
holes by loosening lock nut a maximum of 40 degrees. Install lock
washer bolts to lock nut. Tighten lock washer bolts. Install locking
hub.
LOWER BALL JOINT R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Support
lower control arm enough to release torsion bar tension. Loosen but DO
NOT remove lower ball joint-to-steering knuckle nut.
2) Using ball joint separator, separate ball joint from
steering knuckle. Remove ball joint nut from steering knuckle. Remove
ball joint-to-lower control arm bolts. Remove ball joint.
INSTALLATION

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.

REMOVAL
Remove skid plate (if equipped). Remove stabilizer bar bolt
from lower control arm. Remove stabilizer bar clamp-to-hanger bolts.
Remove stabilizer bar and bushings. Remove stabilizer bar-to-frame
hangers (if necessary).
INSTALLATION
Inspect bushings for wear. Check stabilizer bar for
deformation. To install, reverse removal procedure. Install stabilizer
bar-to-frame hangers and stabilizer bar-to-control arm bolt using new
nuts. Tighten hanger-to-frame nut and stabilizer bar-to-control arm
nut until distance from threaded end of bolt to nut is .24-.32" (6.1-
8.1 mm).
STEERING KNUCKLE R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
brake caliper. Remove hub/rotor assembly. See WHEEL BEARINGS under
REMOVAL & INSTALLATION. Remove dust cover from steering knuckle.
2) Disconnect tie rod end from steering knuckle. Loosen
torsion bar anchor arm assembly adjusting nut. Loosen ball joint-to-
steering knuckle nuts. Using ball joint separator, separate ball
joints from steering knuckle.
3) Detach upper and lower ball joints from steering knuckle.
Remove steering knuckle from drive axle. Remove oil seal and spacer
from steering knuckle.
INSPECTION
Inspect steering knuckle for cracks. Inspect spindle and
steering knuckle needle bearing for wear or damage.
INSTALLATION
1) If needle bearing requires replacement, drive bearing from
steering knuckle. Use Bearing Driver (MB990956-01) and Handle
(MB9909938-01) to install needle bearing.
NOTE: DO NOT reuse steering knuckle bearing if removed.
2) Using bearing installer and handle, install new needle
bearing until bearing is even with steering knuckle end face. Apply
SAE J310 NLGI No. 2 grease to bearing roller surface and spacer-to-
steering knuckle contact areas. Install spacer with chamfered side
toward inside of vehicle.
3) Using Seal Installer (MB990985-01) and Handle (MB990938-\
01), install seal in steering knuckle until seal is even with steering
knuckle end face. Apply grease to seal lip area and inside of seal. To
complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
TORSION BAR R & I
CAUTION: Mark torsion bar and anchor arm location for reassembly
reference before removing.

UPPER CONTROL ARM R & I
REMOVAL
1) Remove shock absorber. Support lower control arm with jack
stand. Remove wheel assembly. Loosen anchor bolt lock nut. See Fig. 1.
2) Mark anchor bolt for reassembly reference. Loosen anchor
bolt to release torsion bar tension. Disconnect and plug brake hose at
frame mount bracket. Remove cotter pin from ball joint stud. Loosen
but DO NOT remove ball joint stud knuckle nut.
3) Using ball joint fork, loosen ball joint from steering
knuckle. Remove ball joint stud nut. Remove rebound stopper and brake
hose support from control arm. Remove upper control arm mounting
bolts. Note direction of bolt installation and location of camber
adjustment shims. Remove control arm.
4) If clearance is inadequate for control arm removal, move
control arm toward rear of vehicle and pull out front part of arm.
Rotate control arm pivot shaft and remove arm. If arm still cannot be
removed, loosen 10 front body mounting nuts. Raise body and remove
arm.
NOTE: On Montero, rotating control arm shaft will alter caster
setting.
INSPECTION
1) Inspect control arm for cracks or deformation. On Montero,
mount control arm in soft-jawed vise using control arm shaft. Attach
spring scale to upper end of control arm, near ball joint.
2) Using spring scale, measure starting torque required to
rotate control arm on the shaft. Replace control arm if starting
torque exceeds 1.4 lbs. (6.5 N).
3) On all models, check ball joints. See BALL JOINT CHECKING
under ADJUSTMENTS & INSPECTION. Inspect ball joint dust cover for
damage and replace as necessary.
INSTALLATION
1) To install, reverse removal procedure. On Montero, ensure
control arm shaft is correctly positioned before installing. Rotate
control arm shaft to obtain correct measurement. See Fig. 6.
Fig. 6: Positioning Upper Control Arm Shaft (Montero)
Courtesy of Mitsubishi Motor Sales of America.
2) On Ram-50 & Pickup, install control arm-to-crossmember
bolts from the inside of crossmember, with nuts against control arm

shaft.
3) On Montero, install control arm-to-crossmember bolts from
the outside of control arm, with nuts against crossmember.
4) Ensure alignment shims are placed in original location.
When installing shock absorber, ensure White paint mark on lower end
of shock faces toward the outside of vehicle. Tighten shock absorber
upper nut until distance from end of threads to nut is .27-.31" (7-8
mm). Install shock lock nut.
5) Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article. Bleed brakes. Adjust anchor bolt to proper
torsion bar setting. See TORSION BAR under REMOVAL & INSTALLATION.
Check wheel alignment and adjust if necessary.
WHEEL BEARINGS R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
caliper assembly. Remove locking hub. See LOCKING HUB under REMOVAL &
INSTALLATION.
2) Remove lock washer. Using Socket (MB990954), remove lock
nut. Remove front hub assembly from steering knuckle.
3) Remove oil seal and bearings from hub. If bearing races
need to be replaced, drive bearing races from hub using brass drift
and hammer.
INSTALLATION
1) Before installing, lubricate outside surfaces of bearing
outer races with grease. Install bearing outer races in hub. Ensure
bearing races are fully seated.
2) Pack bearings with grease. Install inner bearing in hub.
On Montero, install seal in hub using Seal Installer (MB990955). On
Pickup, use Seal Installer (MB990985).
3) Install seal until seal is even with hub surface. To
complete installation, reverse removal procedure. Adjust wheel
bearings. See WHEEL BEARINGS under ADJUSTMENTS & INSPECTION. Tighten
bolts to specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Anchor Bolt Lock Nut ............. 29-36 (39-49)
Automatic Hub Cover .............. 13-25 (18-34)
Ball Joint Nut
Lower ....................... 87-130 (118-176)
Upper .......................... 43-65 (58-88)
Ball Joint-to-Lower
Control Arm Bolt ............... 39-54 (53-73)
Caliper Bolt ..................... 58-72 (79-98)
Control Arm-to-Frame Bolt
Lower ................. ( 1) 101-116 (137-157)
Upper ......................... 72-87 (98-118)
Locking Hub-to-Hub/Rotor Bolt .... 36-43 (49-58)
Manual Hub Cover Bolt .................. 10 (14)
Shock Absorber Lower Mount Bolt
Montero ........................ 11-16 (15-22)
Ram-50 & Pickup ...................... 10 (14)

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* S U SPEN SIO N 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
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS

TIE ROD ENDS (INNER AND OUTER)
TRACK BARS
TRAILING ARMS
WHEEL BEARINGS, RACES AND SEALS
Wheel Alignment
WHEEL ALIGNMENT
Wheels and Tires
TIRES
VALVE STEMS
WHEEL ATTACHMENT HARDWARE
WHEELS (RIMS)
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
1) a Pledge of Assurance to their Customers and 2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-