1991 MITSUBISHI MONTERO Service Manual

4) If control arm bushing needs replacing, use press and
Bushing Remover/Installer (MB990883-01). Press bushing from control
arm. See Fig. 4.
5) Coat bushing and control arm with soapy solution. Using
press and bushing remover/installer, press bushing into control arm.
Position bushing so there is equal distance from bushing-to-control
arm at both ends.
6) Reverse bushing remover/installer to install bushing.
Position bushing so there is equal distance from bushing-to-control
arm at both ends.
CAUTION: Tighten lower control arm shaft and pivot bolt to
specification with vehicle at normal operating height.
INSTALLATION
1) To install, reverse removal procedure. Ensure White mark,
located on lower mounting end of shock absorber, faces toward outside
of vehicle. Tighten lower control arm shaft and pivot bolt to
specification with vehicle at normal operating height.
2) Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article. Install new nut on stabilizer bar-to-control
arm bolt. Tighten stabilizer bar-to-control arm bolt until distance
from threaded end of bolt to nut is .24-.31" (6.0-7.8 mm).
Fig. 3: Replacing Bracket Bushing
Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Replacing Lower Control Arm Bushing
Courtesy of Mitsubishi Motor Sales of America.
STABILIZER BAR R & I

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.

REMOVAL
1) Raise and support vehicle. Support lower control arm with
jack stand. Loosen anchor arm adjusting bolt lock nut. On Montero,
remove heat protector from frame (right side only). Loosen anchor bolt\
to release torsion bar tension.
2) Place reference marks on front of torsion bar, torque arm
and torsion bar-to-torque arm for reassembly reference. Remove anchor
arm. See Fig. 1.
3) Remove dust cover from end of torsion bar. On Montero,
remove heat cover (left side only) located between dust cover and
torsion bar. On all models, remove torsion bar.
INSPECTION
Inspect all splined areas for damage. Inspect dust covers for
cracks or damage. Check for bent anchor bolts. Replace components as
necessary.
INSTALLATION
1) Apply grease to splined areas of torsion bar, anchor arm,
torque arm splines, anchor bolt threads and inside of dust cover.
Check for left and right identification marks on torsion bars' ends.
Ensure torsion bars are installed in correct location.
2) Install torsion bar in torque arm, with identification
mark toward front of vehicle. Align mark on torque arm with mating
mark on torsion bar. When installing a new torsion bar, align the
White paint spline with index mark on front torque arm.
3) Install anchor arm on torsion bar so initial length of
adjusting bolt from flat surface of upper and lower half moon washers
is within specification. See Fig. 5.
4) See ANCHOR BOLT INITIAL SPECIFICATIONS table. Ensure upper
control arm rebound stopper is contacting crossmember before adjusting
initial setting.
NOTE: Ensure upper control arm rebound stopper is contacting
crossmember when adjusting initial settings.
Fig. 5: Adjusting Anchor Arm Bolt
Courtesy of Mitsubishi Motor Sales of America.
ANCHOR BOLT INITIAL SPECIFICATIONS TABLE









\









\









\









\









\

Application In. (mm)
Montero
Left Side .................. 5.3-5.6 (135-142)
Right Side ................. 4.9-5.2 (124-132)
Ram-50 & Pickup
Left Side .................. 5.5-5.8 (140-147)
Right Side ................. 5.3-5.6 (135-142)









\









\









\









\









\





5) After initial torsion bar setting, tighten anchor bolt
adjusting nut to obtain correct final bolt protrusion.
6) On Montero, final bolt protrusion depends upon curb weight
of vehicle. Adjust anchor bolt adjusting nut to obtain final anchor
bolt protrusion. See appropriate FINAL ANCHOR BOLT PROTRUSION table.
FINAL ANCHOR BOLT PROTRUSION TABLE (MONTERO)









\









\









\









\









\









\






Curb Weight Right Bolt Left Bolt
Lbs. (kg) In. (mm) In. (mm)
2910 (1320) ........... 2.6 (65) .............. 2.2 (55)
3000 (1360) ........... 2.7 (68) .............. 2.2 (55)
3080 (1400) ........... 2.8 (71) .............. 2.3 (57)
3170 (1440) ........... 2.8 (71) .............. 2.4 (59)
3260 (1480) ........... 2.9 (72) .............. 2.5 (62)
3350 (1520) ........... 3.0 (76) .............. 2.5 (62)
3440 (1560) ........... 3.0 (76) .............. 2.6 (65)
3530 (1600) ........... 3.1 (78) .............. 2.6 (65)
3620 (1640) ........... 3.2 (80) .............. 2.7 (68)
3700 (1680) ........... 3.2 (80) .............. 2.8 (71)
3790 (1720) ........... 3.3 (84) .............. 2.9 (72)
3880 (1760) ........... 3.4 (86) .............. 2.9 (72)
3970 (1800) ........... 3.4 (86) .............. 3.0 (76)
4060 (1840) ........... 3.5 (88) .............. 3.1 (78)









\









\









\









\









\









\






FINAL ANCHOR BOLT PROTRUSION (RAM-50 & PICKUP)








\









\









\









\









\









\






Right Bolt Left Bolt
Application In. (mm) In. (mm)
Ram-50 & Pickup ..... 3.39 (86.1) ......... 3.94 (100.1)









\









\









\









\









\









\






FINAL ANCHOR BOLT PROTRUSION (1992 MONTERO)








\









\









\









\









\









\






Right Bolt Left Bolt
Application In. (mm) In. (mm)
Montero ............. 3.15 (80.0) .......... 3.15 (80.0)









\









\









\









\









\









\






7) To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end
of article. Place unladed vehicle in normal operating height. Measure
clearance between lower control arm bump stop and bump stop bracket on
frame.
8) On Montero, clearance should be 2.8" (71 mm). On Pickup,
clearance should be 3.1" (78 mm). If clearance measurements are NOT as\
specified, adjust anchor bolt adjusting nut to obtain correct
clearance.

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








\









\









\









\









\





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)

Shock Absorber Shaft Nut ......... 10-13 (14-18)
Tie Rod Nut ............................ 33 (45)
Torque Arm Bolt ................. 69-87 (94-118)
INCH Lbs. (N.m)
Stabilizer Bar Clamp Bolt ........ 84-108 (8-12)
( 1) - Tighten with vehicle at normal operating
height.









\









\









\









\









\