1998 MITSUBISHI MONTERO Service Manual

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Condition Code Procedure
Attaching hardware
bent .................. B .... Require repair or replacement
of bent part.
Attaching hardware
broken ................ A .... Require replacement of broken
part.
Attaching hardware
corroded, affecting
structural integrity .. A .. Require replacement of corroded
part.
Attaching hardware
incorrect ............. A ........... Require replacement of
incorrect part.
Attaching hardware
loose ................. A .... Require repair or replacement
of loose part.
Attaching hardware
missing ............... C ... Require replacement of missing
part.
Attaching hardware
threads damaged ....... A .... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ..... A ...... Require replacement of part
with stripped threads.
Broken (all springs
except secondary
leave(s) on multi-leaf
springs) .............. A ............. Require replacement.
Coil clash ............. .. .. (1) Require ride height check.
Coil spring insulator
deteriorated .......... 2 ........... Suggest replacement of
insulator.
Coil spring insulator
missing ............... 2 ........... Suggest replacement of
insulator.
Coil spring insulator
split ................. 2 ........... Suggest replacement of
insulator.
Coil spring plastic
coating deteriorated -
rust present .......... A ...... ( 2) Refer to manufacturer's
service requirements.
Composite spring
damaged ............... .. .......... ( 3) Further inspection
required.
Cracked (all springs
except composite leaf and
secondary leave(s) on
multi-leaf springs) ... A ............. Require replacement.
Installed incorrectly .. B .................. Require repair.
Leaf spring insulators
missing ............... 2 ........... Suggest replacement of
insulators.
Secondary leaf on multi-
leaf spring broken .... 1 .... Suggest repair or replacement
Secondary leaf on multi-
leaf spring cracked ... 1 .... Suggest repair or replacement
Torsion bar

adjuster bent ......... A ............ (4) Require repair or
replacement of adjuster.
Torsion bar adjuster
seized ................ A .... ( 4) Require repair or replacement
of adjuster.
Torsion bar adjuster
threads damaged ....... A .... ( 4) Require repair or replacement
of part with damaged threads.
Torsion bar adjuster
threads stripped
(threads missing) ..... A ...... Require replacement of part
with stripped threads.
Vehicle suspension height
not within OEM
specifications ........ B ............ Require adjustment or
replacement.
( 1) - If vehicle is within manufacturer's height
specifications, no service is suggested or required.
( 2) - Some manufacturers require replacement under these
conditions.
( 3) - Check vehicle ride height. If ride height is OK, no
service is suggested or required.
( 4) - Only required if ride height needs to be adjusted.









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STEEL POWER STEERING LINES
CAUTION: When replacing steel power steering lines, be sure to use
a replacement product that meets or exceeds OEM design
specifications.
STEEL POWER STEERING LINE INSPECTION









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Condition Code Procedure
Attaching hardware
bent ................... B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Blocked ................. A .. Require repair or replacement.
Fitting incorrect
(such as compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B ........... Required replacement.
Leaking ................. A ........... Require tightening or
replacement.
Line type incorrect ..... B ............ Require replacement.

Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............ 1 ............ Suggest replacement.
Rust pitted, affecting
structural integrity .. A ............ Require replacement.









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STEERING ARMS
STEERING ARM INSPECTION








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Condition Code Procedure
Attaching hardware
bent ................... B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Taper hole elongated .... A ........ ( 1) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Check for damaged stud.









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STEERING DAMPERS
The following procedures are only required if the vehicle was
originally equipped from the factory with a steering damper. If the
steering damper is an add-on unit, then the unit may be removed
instead of repairing or replacing.
STEERING DAMPER INSPECTION









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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part, if available;
otherwise, replace steering
damper.
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,

replace steering damper.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part, if available; otherwise,
replace steering damper.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace steering
damper.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace steering
damper.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace steering damper.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace steering damper.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
steering damper.
Binding ................. A ............ Require replacement.
Damper body dented ...... A .......... (1) Further inspection
required.
Damper body punctured ... A ............ Require replacement.
Damping (none) .......... A ............ Require replacement.
Dust boot (bellows)
missing ................ 2 ......... ( 2) Suggest replacement
of boot.
Dust boot (bellows)
split .................. 2 ......... ( 2) Suggest replacement
of boot.
Dust shield broken ...... 2 ........ ( 2) Suggest replacement.
Dust shield missing ..... 2 ........ ( 2) Suggest replacement.
Leaking oil, enough for
fluid to be running
down the body .......... A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noise ................... 2 .......... ( 3) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Piston rod has surface
defect ................. 2 ............ Suggest replacement.
Piston rod threads
stripped (threads
missing) ............... A ............ Require replacement.
Piston rod threads
damaged ................ A .. Require repair or replacement.
Seized .................. A ............ Require replacement.
( 1) - Require replacement of units where dents restrict damper

piston rod movement. If dents don't restrict movement, no
service is suggested or required. Especially critical on
mono-tube dampers.
(2) - This condition can lead to damage of the piston rod,
which, in turn, causes premature piston rod seal wear.
( 3) - If noise is isolated to damper, suggest replacement.









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STEERING GEARS (EXCEPT RACK AND PINION)
If diagnosis has determined that complete disassembly is
necessary to determine the extent of the system failure, the
suggestion may be made to rebuild or replace the power steering pump.
Repair or replacement of the following components may be required, if
performed as part of a power steering pump overhaul or rebuild service
to meet a minimum rebuild standard.
STEERING GEAR (EXCEPT RACK AND PINION) INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A .. Require replacement of broken
part.
Attaching hardware
loose .................. A .. Require repair or replacement
of loose part.
Attaching hardware
missing ................ C ......... Require replacement of
missing part.
Attaching hardware
threads damaged ........ A .. Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A .... Require replacement of part
with stripped threads.
Binding ................. A ... Require repair or replacement
Flex coupler binding .... A ... Require repair or replacement
of coupler.
Flex coupler loose ...... A ... Require repair or replacement
of coupler.
Flex coupler
missing parts .......... A ... Require repair or replacement
of coupler.
Flex coupler
soft/spongy ............ A . Require replacement of coupler.
Flex coupler torn ....... A . Require replacement of coupler.
Fluid contaminated ...... B ........ ( 1) Require flushing and
refilling of the system.
Gasket leaking .......... A ... Require repair or replacement
of gasket.
Housing leaking ......... A ............ Require replacement.
Hydraulic fittings
leaking ................ A ... Require repair or replacement
of fittings.
Inadequate power assist . A .......... ( 2) Further inspection
required.
See note below.
Lash exceeds
manufacturer's
specifications .......... B .. Require repair or replacement.
Seal leaking ............ A ... Require repair or replacement

of seal and/or mating part.
Splines damaged ......... A ... Require repair or replacement
of splines.
Splines stripped ........ A . Require replacement of splines.
Steering coupler
shield cracked ......... 2 ............ Suggest replacement.
Steering coupler
shield missing ......... C ............ Require replacement.
Threads damaged ......... A ... Require repair or replacement
of part with damaged threads.
Threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
U-joint binding ......... A ... Require repair or replacement
of joint.
U-joint loose ........... A ... Require repair or replacement
of joint.
Unequal power assist .... A .. Require repair or replacement.
(1) - Determine and correct source of contamination. OEM
specifications must be followed for fluid type.
( 2) - If steering gear is source of inadequate assist, require
repair or replacement.









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STEERING GEARS - RACK AND PINION
If diagnosis has determined that complete disassembly is
necessary to determine the extent of the system failure, the
suggestion may be made to rebuild or replace the power steering pump.
Repair or replacement of the following components may be required, if
performed as part of a power steering pump overhaul or rebuild service
to meet a minimum rebuild standard.
STEERING GEARS - RACK AND PINION INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ......... Require replacement of
broken part.
Attaching hardware
loose .................. A .. Require repair or replacement
of loose part.
Attaching hardware
missing ................ C ......... Require replacement of
missing part.
Attaching hardware
threads damaged ........ A .. Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A .... Require replacement of part
with stripped threads.
Balance tube blocked .... A .. Require repair or replacement
of balance tube.
Balance tube missing .... C .. Require replacement of balance
tube.
Balance tube restricted . A ... Require repair or replacement
of balance tube.
Bellows boot
clamp missing .......... C ... Require replacement of clamp.
Bellows boot cracked

(not through) .......... 2 .. Suggest replacement of bellows
boot.
Bellows boot missing .... C .. Require replacement of bellows
boot.
Bellows boot
not sealing ............ A ... Require repair or replacement
of bellows boot.
Bellows boot torn ....... A .. Require replacement of bellows
boot.
Bellows boot twisted
(from toe adjustment) .. B ................. Require repair.
Fitting leaking ......... A .. Require repair or replacement.
Fitting missing ......... A . Require replacement of fitting.
Fitting threads
damaged ................ A ... Require repair or replacement
of part with damaged threads.
Fitting threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Flex coupler binding .... A ... Require repair or replacement
of coupler.
Flex coupler loose ...... A ... Require repair or replacement
of coupler.
Flex coupler
missing parts .......... A ... Require repair or replacement
of coupler.
Flex coupler
soft/spongy ............ A . Require replacement of coupler.
Flex coupler torn ....... A . Require replacement of coupler.
Fluid contaminated ...... B ........ (1) Require flushing and
refilling of the system.
Gasket leaking .......... A .. Require repair or replacement.
Hard steering on cold
start-up ............... 1 ........... ( 2) Suggest repair or
replacement.
Housing cracked,
affecting structural
integrity .............. B ............ Require replacement.
Housing leaking ......... A ............ Require replacement.
Inadequate power assist . A .......... ( 3) Further inspection
required.
Lash exceeds
manufacturer's
specifications ......... B .. Require repair or replacement.
Seal leaking ............ A .. Require repair or replacement.
Splines damaged ......... A .. Require repair or replacement.
Splines stripped
(splines missing) ...... A ............ Require replacement.
Steel line blocked ...... A ... Require repair or replacement
of line.
Steel line leaking ...... A ... Require repair or replacement
of line.
Steel line missing ...... C .... Require replacement of line.
Steel line restricted ... A ... Require repair or replacement
of line.
Steering coupler shield
cracked ................ 2 ............ Suggest replacement.
Steering coupler shield
missing ................ C ............ Require replacement.
Steering coupler shield
torn ................... 2 ............ Suggest replacement.
Threads damaged ......... A ... Require repair or replacement
of part with damaged threads.

Threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
U-joint binding ......... A ... Require repair or replacement
of joint.
U-joint loose ........... A ... Require repair or replacement
of joint.
Unequal power assist .... A .. Require repair or replacement.
(1) - Determine and correct source of contamination. Follow OE
specifications for fluid type.
( 2) - Indicates internal wear.
( 3) - If steering gear is source of inadequate assist, require
repair or replacement.









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STEERING KNUCKLES
STEERING KNUCKLE INSPECTION








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Condition Code Procedure
Attaching hardware
bent ................... B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Pinch bolt incorrect .... B ... Require replacement with bolt
that meets OE design.
Pinch bolt loose ........ B ................. Require repair.
Pinch bolt missing ...... B ............ Require replacement.
Pinch bolt tabs
deformed (pinched
together), .032"
or more before
clamping ............... B ........ ( 1) Require replacement.
Taper hole elongated .... A ........ ( 2) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
( 1) - Steering knuckle deformation can cause pinch
bolt breakage.
( 2) - Check for damaged stud.