1998 MITSUBISHI MONTERO transmission

90,000 MILE (144,000 KM) NORMAL SERVICE
\
\
\
\
\
\
\
 
VERIFY 
\b
\
\
\
\
\
\
\




Last Major Service Was Performed 
\b
\
\
\
\
\
\
\




SERVICE 
\b
\
\
\
\
\
\
\



 Ball Joints With Grease Nipple (
6) 
\b
 \
\
\
\
\
\
\



 Propeller Shaft Joints (
6) 
\b
\
\
\
\
\
\
\




INSPECT 
\b
\
\
\
\
\
\
\



 Fuel Hoses (
3) 
\b
 \
\
\
\
\
\
\



 Drive Belt (For Generator, Water Pump, Power Steering Pump) 
\b
 \
\
\
\
\
\
\



 Manual Transmission Oil 
\b
 \
\
\
\
\
\
\



 Transfer Oil 
\b
 \
\
\
\
\
\
\



 Disc Brake Pads (
4) 
\b
 \
\
\
\
\
\
\



 Brake Hoses (
4) 
\b
 \
\
\
\
\
\
\



 Ball Joint & Steering Linkage Seals (
3) 
\b
 \
\
\
\
\
\
\



 Drive Shaft Boots (
4) 
\b
 \
\
\
\
\
\
\



 Exhaust System (
3) 
\b
\
\
\
\
\
\
\




REPLACE 
\b
\
\
\
\
\
\
\



 Engine Oil (
1) 
\b
 \
\
\
\
\
\
\



 Engine Oil Filter (
2) 
\b
 \
\
\
\
\
\
\



 Engine Coolant 
\b
 \
\
\
\
\
\
\



 Automatic Transmission Fluid 
\b
 \
\
\
\
\
\
\



 Rear Axle Oil 
\b
 \
\
\
\
\
\
\



 Air Cleaner Filter 
\b
\
\
\
\
\
\
\



(
1) - Change once a year or every 7,500 miles (12,000 KM). 

(
2) - If mileage is less than 7,500 miles (12,000 KM) each year, 

replace the oil filter at every oil change. 

(
3) - Or inspect every 2 years. 

(
4) - Or inspect every year. 

(
5) - Or change every 2 years. 

(
6) - Or lubricate grease every 2 years. 
\b
\
\
\
\
\
\
\




LUBRICATION SPECIFICATIONS 
\b
\
\
\
\
\
\
\




Material  Condition  Specification 
\b
\
 \
\
\
 \
\
\



Engine Oil  Ambient Temperature Less Than SAE 5W-30 

(
1)  0F (-18C) To 100F (38C)  

\b
\
\
\
 \
\



Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  

\b\
 \
\
\
 \
\
\



Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 
\b
\
 \
\
\
 \
\
\



Manual  All API Classification GL-4

Transmission   SAE 75W-85W Or 75W-90 
\b
\
 \
\
\
 \
\
\



Automatic  All  "ATF DEXRON II" Or 

Transmission   Equivalent 
\b
\
 \
\
\
 \
\
\



Brake Fluid  All  DOT 3 Or DOT 4 
\b
\
 \
\
\
 \
\
\



Rear Axle  All API Classification GL-5

  Or Higher (
2) 
\b
\
 \
\
\
 \
\
\



Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 
\b
\
\
\
\
\
\
\





(
1) - SAE 5W-30 engine oil is preferred. SAE 10W-30 may be used if 

the Ambient Temperature is above 0 F (-18 C). 

(
2) - SAE90, 85W-90, 80W-90 may be used in temperatures above 

-10 F (-23 C). SAE 80W, 80W-90 may be used in temperatures 

from -30 F (-34 C) to -10 F (-23 C). SAE 75W may be used 

in temperatures below -30 F (-34 C). 
\b
\
\
\
\
\
\
\




FLUID CAPACITIES 
\b
\
\
\
\
\
\
\




Item  Condition  Specification (1) 
\b
\
 \
\
\
 \
\
\



Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

(
1) \b \
\
\
 \
\



 Oil Filter  0.32 Qts. (0.3L) 

\b
\
\
\
 \
\



 Oil Cooler  0.32 Qts. (0.3L) 
\b
\
 \
\
\
 \
\
\



Engine  Drained; With Reserve Tank  10 Qts. (9.5L) 

Coolant   
\b
\
 \
\
\
 \
\
\



Automatic  Drained  8.9 Qts. (8.5L) 

Transmission   
\b
\
 \
\
\
 \
\
\



Manual  Drained  3.3 Qts. (3.2L) 

Transmission   
\b
\
 \
\
\
 \
\
\



Rear Axle  Drained  3.3 Qts. (3.2L) 
\b
\
 \
\
\
 \
\
\



Transfer Case Drained  2.6 Qts. (2.5L) 
\b
\
\
\
\
\
\
\



(
1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
\f
\
\
\
\
\
\
\


97,500 MILE (156,000 KM) NORMAL SERVICE
97,500 MILE (156,000 KM) NORMAL SERVICE
\
\
\
\
\
\
\
 
VERIFY 
\b
\
\
\
\
\
\
\




Last Major Service Was Performed 
\b
\
\
\
\
\
\
\


 FLUID CAPACITIES 
\b
\
\
\
\
\
\
\




Item  Condition  Specification (1) 
\b
\
 \
\
\
 \
\
\



Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

(
1) \b \
\
\
 \
\



 Oil Filter  0.32 Qts. (0.3L) 

\b
\
\
\
 \
\



 Oil Cooler  0.32 Qts. (0.3L) 
\b
\
\
\
\
\
\
\



(
1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
\f
\
\
\
\
\
\
\


120,000 MILE (200,000 KM) NORMAL SERVICE
120,000 MILE (200,000 KM) NORMAL SERVICE
\
\
\
\
\
\
\
 
VERIFY 
\b
\
\
\
\
\
\
\




Last Major Service Was Performed 
\b
\
\
\
\
\
\
\




SERVICE 
\b
\
\
\
\
\
\
\



 Ball Joints With Grease Nipple (
6) 
\b
 \
\
\
\
\
\
\



 Propeller Shaft Joints (
6) 
\b
\
\
\
\
\
\
\




INSPECT 
\b
\
\
\
\
\
\
\



 Fuel Hoses (
3) 
\b
 \
\
\
\
\
\
\



 Fuel System (Tank, Pipe Line, Connection & Fuel Tank Filler 

 Tube Cap) (
3) 
\b
 \
\
\
\
\
\
\



 Evaporative Emission Control System (Except Evaporative 

 Emission Canister) (
7) 
\b
 \
\
\
\
\
\
\



 Drive Belt (For Generator, Water Pump, Power Steering Pump) 
\b
 \
\
\
\
\
\
\



 Manual Transmission Oil 
\b
 \
\
\
\
\
\
\



 Transfer Oil 
\b
 \
\
\
\
\
\
\



 Disc Brake Pads (
4) 
\b
 \
\
\
\
\
\
\



 Brake Hoses (
4) 
\b
 \
\
\
\
\
\
\



 Ball Joint & Steering Linkage Seals (
3) 
\b
 \
\
\
\
\
\
\



 Drive Shaft Boots (
4) 
\b
 \
\
\
\
\
\
\



 Exhaust System (
3) 
\b
 \
\
\
\
\
\
\



 Distributor Cap & Rotor (
7) 
\b
\
\
\
\
\
\
\




REPLACE 
\b
\
\
\
\
\
\
\



 Engine Oil (
1) 
\b
 \
\
\
\
\
\
\



 Engine Oil Filter (
2) 
\b
 \
\
\
\
\
\
\


  Engine Coolant 
\b
 \
\
\
\
\
\
\



 Automatic Transmission Fluid 
\b
 \
\
\
\
\
\
\



 Rear Axle Oil 
\b
 \
\
\
\
\
\
\



 Spark Plugs 
\b
 \
\
\
\
\
\
\



 Timing Belt (
9) 
\b
 \
\
\
\
\
\
\



 Ignition Cables (
8) 
\b
 \
\
\
\
\
\
\



 Air Cleaner Filter 
\b
\
\
\
\
\
\
\



(
1) - Change once a year or every 7,500 miles (12,000 KM). 

(
2) - If mileage is less than 7,500 miles (12,000 KM) each year, 

replace the oil filter at every oil change. 

(
3) - Or inspect every 2 years. 

(
4) - Or inspect every year. 

(
5) - Or change every 2 years. 

(
6) - Or lubricate grease every 2 years. 

(
7) - Or inspect every 5 years. 

(
8) - Or replace every 5 years. 

(
9) - For California & Massachusettes, this maintenance is 

recommended but not required. 
\b
\
\
\
\
\
\
\




LUBRICATION SPECIFICATIONS 
\b
\
\
\
\
\
\
\




Material  Condition  Specification 
\b
\
 \
\
\
 \
\
\



Engine Oil  Ambient Temperature Less Than SAE 5W-30 

(
1)  0F (-18C) To 100F (38C)  

\b
\
\
\
 \
\



Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  
\b
\
 \
\
\
 \
\
\



Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 
\b
\
 \
\
\
 \
\
\



Manual  All API Classification GL-4

Transmission   SAE 75W-85W Or 75W-90 
\b
\
 \
\
\
 \
\
\



Automatic  All  "ATF DEXRON II" Or 

Transmission   Equivalent 
\b
\
 \
\
\
 \
\
\



Brake Fluid  All  DOT 3 Or DOT 4 
\b
\
 \
\
\
 \
\
\



Rear Axle  All API Classification GL-5

  Or Higher (
2) 
\b
\
 \
\
\
 \
\
\



Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 
\b
\
\
\
\
\
\
\



(
1) - SAE 5W-30 engine oil is preferred. SAE 10W-30 may be used if 

the Ambient Temperature is above 0 F (-18 C). 

(
2) - SAE90, 85W-90, 80W-90 may be used in temperatures above 

-10 F (-23 C). SAE 80W, 80W-90 may be used in temperatures 

from -30 F (-34 C) to -10 F (-23 C). SAE 75W may be used 

in temperatures below -30 F (-34 C). 
\b
\
\
\
\
\
\
\




FLUID CAPACITIES 
\b
\
\
\
\
\
\
\


 Item  Condition  Specification (1) 
\b
\
 \
\
\
 \
\
\



Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

(
1) \b \
\
\
 \
\



 Oil Filter  0.32 Qts. (0.3L) 

\b
\
\
\
 \
\



 Oil Cooler  0.32 Qts. (0.3L) 
\b
\
 \
\
\
 \
\
\



Engine  Drained; With Reserve Tank  10 Qts. (9.5L) 

Coolant   
\b
\
 \
\
\
 \
\
\



Automatic  Drained  8.9 Qts. (8.5L) 

Transmission   
\b
\
 \
\
\
 \
\
\



Manual  Drained  3.3 Qts. (3.2L) 

Transmission   
\b
\
 \
\
\
 \
\
\



Rear Axle  Drained  3.3 Qts. (3.2L) 
\b
\
 \
\
\
 \
\
\



Transfer Case Drained  2.6 Qts. (2.5L) 
\b
\
\
\
\
\
\
\



(
1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
\f
\
\
\
\
\
\
\


LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE
\
\
\
\
\
\
\
 
Material  Condition  Specification 
\b
\
 \
\
\
 \
\
\



Engine Oil Ambient Temperature Less Than  SAE 5W-30 

(
1)  0F (-18C) To 100F (38C)  

\b
\
\
\
 \
\



Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  
\b
\
 \
\
\
 \
\
\



Power  All Automatic Transmission 

Steering   Fluid DEXRON II 

Fluid   
\b
\
 \
\
\
 \
\
\



Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 
\b
\
 \
\
\
 \
\
\



Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 
\b
\
 \
\
\
 \
\
\



Front Axle  All API Classification GL-5

  Or Higher (
2) 
\b
\
 \
\
\
 \
\
\



Clutch Fluid  All  DOT 3 Or DOT 4 
\b
\
 \
\
\
 \
\
\



Hook Lock  All  Multipurpose Grease 

Catch, Door   NLGI Grade 2 

Lock Strikers  

Seat Adjust-   

ers, Backdoor  

Lock, Parking  

Brake Cable   

Mechanism   
\b
\
 \
\
\
 \
\
\


 Front Wheel  All  Multipurpose Grease 

Bearings   NLGI Grade 2 Or 

  Equivalent 
\b
\
 \
\
\
 \
\
\



Door Hinges, All  Engine Oil 

Back Door   

Hinges   
\b
\
 \
\
\
 \
\
\



A/C  All  HFC-134a 

Refrigerant   
\b
\
 \
\
\
 \
\
\



Manual  All API Classification GL-4

Transmission   SAE 75W-85W Or 75W-90 
\b
\
 \
\
\
 \
\
\



Automatic  All  "ATF DEXRON II" Or 

Transmission   Equivalent 
\b
\
 \
\
\
 \
\
\



Brake Fluid  All  DOT 3 Or DOT 4 
\b
\
 \
\
\
 \
\
\



Rear Axle  All API Classification GL-5

  Or Higher (
2) 
\b
\
\
\
\
\
\
\





(
1) - SAE 5W-30 engine oil is preferred. SAE 10W-30 may be used if 

the Ambient Temperature is above 0 F (-18 C). 

(
2) - SAE90, 85W-90, 80W-90 may be used in temperatures above 

-10 F (-23 C). SAE 80W, 80W-90 may be used in temperatures 

from -30 F (-34 C) to -10 F (-23 C). SAE 75W may be used 

in temperatures below -30 F (-34 C). 
\f
\
\
\
\
\
\
\


FLUID CAPACITIES
FLUID CAPACITIES TABLE ( 1)
\
\
\
\
\
\
\
 
Item  Condition  Specification 
\b
\
 \
\
\
 \
\
\



Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

(
1) \b \
\
\
 \
\



 Oil Filter  0.32 Qts. (0.3L) 

\b
\
\
\
 \
\



 Oil Cooler  0.32 Qts. (0.3L) 
\b
\
 \
\
\
 \
\
\



Power  Drained  1.1 Qts. (1.0L) 

Steering   
\b
\
 \
\
\
 \
\
\



Automatic  Drained  8.9 Qts. (8.5L) 

Transmission   
\b
\
 \
\
\
 \
\
\



Manual  Drained  3.3 Qts. (3.2L) 

Transmission   
\b
\
 \
\
\
 \
\
\



Transfer Case Drained  2.6 Qts. (2.5L) 
\b
\
 \
\
\
 \
\
\



Front Axle  Drained  1.3 Qts. (1.2L) 
\b
\
 \
\
\
 \
\
\



Rear Axle  Drained  3.3 Qts. (3.2L) 
\b
\
 \
\
\
 \
\
\



A/C  Drained  27 oz (760 g) 

Refrigerant   
\b
\
 \
\
\
 \
\
\



Fuel Tank  Capacity  24 gal (92L) 

ARMATURE TEST
Ensure armature is not grounded. Place armature in growler.
Hold a thin steel blade parallel and just above armature while slowly
rotating armature in growler. A shorted armature will cause blade to
vibrate and be attracted to core. Using an ohmmeter, check continuity
between armature coil cores and commutator segments (small diameter
end of armature). Continuity should not exist. Check for continuity
between segments. Continuity should exist. Replace armature as
necessary.
BRUSH HOLDER TEST
Using an ohmmeter, check continuity between brush holder
plate and brush holder. Continuity should not exist. Replace brush
holder as necessary.
REMOVAL & INSTALLATION
NOTE: On Montero with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
Removal & Installation
Disconnect negative battery cable. If necessary, raise
vehicle on hoist. Remove starter mounting bolts and starter. To
install, reverse removal procedure.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP MEASUREMENT under BENCH TESTING. See Figs. 5 and
6.
Fig. 5: Exploded View Of Direct Drive Starter (Typical)
Courtesy of Mitsubishi Motor Sales of America

cross shaft and rack piston for wear and damage. Check contact part of
adjusting bolt for uneven wear. Check dust seal, oil seal and "O"
rings for wear and damage.
Reassembly
1) Install NEW cross shaft lower "U" packing (if removed).
Press lower cross shaft oil seal into gearbox housing. See Fig. 3.
Press bearing and oil seal into top cover. Install bearing race and
"O" ring.
2) Apply transmission fluid to seal ring contact areas on
mainshaft, and install seal rings firmly into valve grooves. Wrap
serrated part of mainshaft with vinyl tape. Mount valve body to valve
housing. Install cage and align hole in cage with channel in
mainshaft. Install bearing race and insert balls.
3) Install mainshaft into valve housing while pressing on
bearing race to prevent balls from falling out. Using spanner wrench,
install lock nut and tighten until it contacts bearing race.
4) Tighten lock nut while measuring mainshaft endplay using
dial indicator. When mainshaft endplay is .001" (.003 mm), use a punch\
to crimp circumference of lock nut. Ensure mainshaft rotates freely.
5) Apply transmission fluid to "O" ring and piston seal ring,
and install into gearbox housing. Install rack piston until it
contacts edge of mainshaft. Rotate mainshaft to align ball raceway
with insertion hole. Install 19 balls.
NOTE: Insert balls so no clearance exists between balls.
6) Place remaining 7 balls in circulator and install
circulator to rack piston. Install circulator holder. Install NEW
cross shaft upper "U" packing (if removed). Install upper cross shaft
"O" ring. Apply transmission fluid to rack piston seal ring and insert
valve housing. Rotate mainshaft until rack piston is centered (neutral
position).
7) Install adjusting plate so beveled part is facing upward.
Using a feeler gauge, measure clearance between adjusting bolt and
cross shaft. If clearance is greater than .002" (.05 mm), replace with\
appropriate adjusting plate.
8) Apply multipurpose grease to seal surface of "U" packing.
Apply transmission fluid to cross shaft teeth and side cover "O" ring.
Install cross shaft to side cover, and temporarily tighten adjusting
bolt lock nut.
CAUTION: DO NOT rotate side cover during installation, or damage to
cross shaft oil seal may result.
9) Apply transmission fluid to rack piston teeth and shaft
areas. Apply multipurpose grease to oil seal lip. Install side cover
assembly (with cross shaft) to gearbox.
10) Position mainshaft in straight-ahead position. While
turning adjusting bolt, measure mainshaft combined starting torque
using Preload Socket (MB990228-01) and an INCH-lb. torque wrench.
Combined starting torque should be 4-11 INCH lbs. (.5-1.3 N.m). Center\
reading should be 2 INCH lbs. (.2 N.m) higher than reading at either
end.
11) Tighten adjusting bolt lock nut to specification. See
TORQUE SPECIFICATIONS . Install pitman arm with mating marks aligned.
POWER STEERING PUMP
Disassembly
1) Remove suction connector bolts. Mount pump in a soft-jawed
vise. Remove pump cover bolts and cover. Using a plastic mallet, tap
pulley assembly shaft from pump housing. See Fig. 4.