1991 MITSUBISHI MONTERO Service Manual

Fig. 4: Switch Testing and R & I (Galant)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 5: Switch Testing and R & I (Montero)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Switch Testing and R & I (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Switch Testing and R & I (Stealth & 3000GT)
Courtesy of Mitsubishi Motor Sales of America.

\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

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

Lubricate ball joint with SAE J310 NLGI No. 2 grease. Apply
semi-drying sealant to ball joint grooves. Reverse removal procedure
to complete installation. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table at end of article.
NOTE: On Ram-50 and Pickup, replace upper control arm if ball
joint is defective.
UPPER BALL JOINT R & I (MONTERO)
REMOVAL
Remove snap ring and dust cover together from ball joint. See
Fig. 1 . Use Ball Joint Remover/Installer (MB990799-01 and MB990800-01)
and Clamp (MB990840-01) to press ball joint from control arm. Tighten
clamp to remove ball joint.
INSTALLATION
1) Before installing, align reference mark on ball joint with
center of control arm. Using bushing remover/installers, install ball
joint in control arm. See Fig. 1.
2) Install snap ring on ball joint. Lubricate ball joint with
SAE J310 NLGI No. 2 grease. Apply semi-drying sealant to ball joint
grooves. Install new dust cover and ring.
AUTOMATIC TYPE LOCKING HUB R & I
REMOVAL
1) Place hub must in the FREE position by placing transfer
case lever in 2H position and moving vehicle in Reverse approximately
4-6 feet.
2) Remove cover from locking hub. If necessary, wrap shop
towel around cover and use an oil filter wrench to loosen cover. Raise
and support vehicle. Remove wheel assembly.
3) Using snap ring pliers, remove snap ring and shim from end
of drive axle. See Fig. 2. Using hexagonal wrench, remove locking hub
retaining bolts. Remove locking hub assembly.
Fig. 2: Exploded View of Automatic Locking Hub
Courtesy of Chrysler Motors.
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.