1998 MITSUBISHI MONTERO Service Manual

98V205000: THIRD-SEAT LATCH & STRIKER INSPECTION
1998 Mitsubishi Montero
NHTSA RECALL BULLETIN
Model(s): 1994-98 Mitsubishi Montero
Campaign No: 98V205000
Number of Affected Vehicles: 60243
VEHICLE DESCRIPTION:
Passenger vehicles equipped with accessory cargo mats in
the third-seat and cargo area.
DESCRIPTION OF DEFECT:
This cargo mat interferes with the latching integrity of the folding
third seats.
CONSEQUENCE OF DEFECT:
In the event of a crash, an occupant of the third seat may not be
properly restrained and could be ejected from the vehicle.
CORRECTIVE ACTION:
Dealers will inspect the third-seat latch and striker. A rectangle
will be removed from the cargo mat around each striker to provide
adequate striker clearance and proper latching.
OWNER NOTIFICATION:
Owner notification is expected to begin October 12, 1998.
Owners who take their vehicles to an authorized dealer on an agreed
upon service date and do not receive the free remedy within a
reasonable time should contact Mitsubishi at 1-800-222-0037. Also
contact the National Highway Traffic Safety Administration's Auto
Safety Hotline at 1-888-dash-2-dot (1-888-327-4236).
ADDITIONAL INFORMATION:
The National Highway Traffic Safety Administration operates Monday
through Friday from 8:00 AM to 4:00 PM, Eastern Time. For more
information call (800) 424-9393 or (202) 366-0123. For the hearing
impaired, call (800) 424-9153.

TRANSMISSION REMOVAL & INSTALLATION - A/T
1998 Mitsubishi Montero
1997-98 TRANSMISSION SERVICING
Mitsubishi Transmission Removal & Installation
Diamante, Eclipse, Galant, Mirage, Montero, 3000GT
REMOVAL & INSTALLATION
AWD & FWD MODELS
Removal
1) On all models except Galant, remove battery and battery
tray. On 3000GT, remove washer tank. On all models, remove air cleaner
cover with air inlet hose assembly. Raise and support vehicle. Remove
wheels. Remove undercover(s) (if equipped). Disconnect control cable\
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at transaxle. Drain transaxle fluid.
2) On AWD models, remove front exhaust pipe. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) Separate tie rod end. Separate lower ball joint. Separate
stabilizer bar connection (if necessary). Remove axle shafts. See
appropriate AXLE SHAFTS article in DRIVE AXLES. Remove center
crossmember assembly.
4) On AWD models, separate transfer assembly from transaxle.
Reference mark transfer assembly-to-drive shaft and remove transfer
assembly.
5) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
6) On all 4-cylinder models, support engine. On all models,
support transaxle with jack. Remove bolts from transaxle mounts.
Remove mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
Installation
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS .
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
RWD & 4WD MODELS
Removal
1) Disconnect negative battery cable. On Montero 4WD, remove
transfer case shift lever knob, dust boot and retainer plate or
console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\

and remove. Disconnect all external solenoid and switch connections.
3) On Montero 4WD, remove catalytic converter and front
exhaust pipe. On all models, disconnect speedometer cable and control
cables at transmission. Remove starter and bellhousing cover. Place
reference mark on torque converter and drive plate for reassembly
reference. Remove torque converter bolts. Push torque converter back
and away from drive plate.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
Installation
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS. Tighten mount bolts with
weight of engine and transmission on mounts. Ensure reference marks on
drive shaft(s) and torque converter-to-drive plate are matched.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS - FWD MODELS








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Applications Ft. Lbs. (N.m)\
Ball Joint Nut ............................................ 74 (100)\
Center Crossmember Assembly Front Bolt ..................... 69 (93)\
Center Crossmember Assembly Rear Bolt ...................... 52 (70)\
Starter Bolts .............................................. 22 (30)\
Tie Rod End Nut ............................................ 21 (28)\
Torque Converter-To-Drive Plate Bolt ................. 33-38 (45-52)\
Transaxle-To-Engine Block Bolt
8-mm Bolt .................................................... ( 1)
10-mm Bolt ......................................... 22-25 (30-34)\
12-mm Bolt ......................................... 31-40 (42-54)\
Upper Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 54 (73)\
Lower Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 65 (88)\
( 1) - Tighten to 84-108 INCH lbs. (10-12 N.m).









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TORQUE SPECIFICATIONS - RWD MODELS








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Applications Ft. Lbs. (N.m)\
Engine-To-Transmission Bolt ................................ 65 (88)\

Torque Converter-To-Drive Plate Bolt ....................... 30 (41)\
Transmission-To-Engine Block Bolt .......................... 55 (74)\









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TRANSMISSION SERVICING - A/T
1998 Mitsubishi Montero
1997-98 TRANSMISSION SERVICING
Mitsubishi Automatic Transmission
Diamante, Eclipse, Galant, Mirage, Montero, 3000GT
IDENTIFICATION
AUTOMATIC TRANSMISSION APPLICATIONS








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Model Transmission/Transaxle
Diamante ..................................... Model F4A51 Transaxle
Eclipse
AWD ........................................ Model W4A33 Transaxle
FWD
2.0L Non-Turbo ........................... Model F4AC1 Transaxle
2.0L Turbo ............................... Model F4A33 Transaxle
2.4L ....................................... Model F4A23 Transaxle
Galant ....................................... Model F4A23 Transaxle
Mirage
1.5L ....................................... Model F4A41 Transaxle
1.8L ....................................... Model F4A42 Transaxle
Montero
2WD ..................................... Model R4AW3 Transmission
4WD ..................................... Model V4AW3 Transmission
3000GT ....................................... Model F4A33 Transaxle









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LUBRICATION
SERVICE INTERVALS
Transaxle/Transmission
Check fluid level every 12 months or 15,000 miles. Change
fluid and filter every 30,000 miles. If vehicle is operated under
severe conditions, change fluid more often. If severe darkening of
fluid and strong odor are noted, bands should also be adjusted.
Transfer Case
On 4WD and AWD models, change transfer case fluid every 30,
000 miles.
CHECKING FLUID LEVEL
Transaxle/Transmission
1) Park vehicle on level area. Ensure oil is at normal
operating temperature, parking brake is engaged, and engine is at
idle. Move gear selector through each position, stopping briefly at
each selection.
2) Place gear selector in Neutral, and clean area around
dipstick tube. Ensure fluid level is between lower and upper marks,
but never over upper mark, in HOT range. Add or drain fluid if
necessary.
CAUTION: If severe darkening of fluid and strong odor are noted,
change fluid and filter, and adjust bands.
Transfer Case (All Others)

Lubricant level should be to bottom of fill hole on side of
transfer case.
RECOMMENDED FLUID
Transaxle/Transmission
Except Montero, use Diamond ATF SP-II. On Montero, use
Dexron-II ATF.
Transfer Cases
Use SAE 75W-85 gear oil with API GL-4 rating or higher.
FLUID CAPACITIES
TRANSAXLE/TRANSMISSION REFILL CAPACITIES








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Application Qts. (L)\
Diamante ................................................. 9.0 (8.5)\
Eclipse
2.0L Non-Turbo ......................................... 9.1 (8.6)\
2.0L Turbo ............................................. 7.1 (6.7)\
2.4L ................................................... 6.4 (6.1)\
Galant ................................................... 6.3 (6.0)\
Mirage ................................................... 8.2 (7.8)\
Montero ................................................. 10.4 (9.8)\
3000GT ................................................... 7.9 (7.5)\









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TRANSFER CASE REFILL CAPACITIES








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Application Pts. (L)\
Eclipse AWD ............................................... 1.0 (.5)\
Montero .................................................. 5.3 (2.5)\
Montero Sport ............................................ 4.9 (2.3)\
3000GT ..................................................... .6 (.3)\









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DRAINING & REFILLING
NOTE: Although manufacturer recommends changing only fluid, the
oil filter/screen may also require replacement. If replacing
oil filter/screen, note length and location of all bolts.
Transaxle (Except Montero)
1) Remove drain plug(s), and drain fluid. Some models may
contain a drain plug located in housing below axle shaft, in oil pan.
Remove oil pan. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS . Clean oil pan, replace
gasket, and install oil pan. Tighten oil pan bolts and drain plug to
specification. See TORQUE SPECIFICATIONS . Ensure dipstick hole area is
clean. Fill transmission with Diamond ATF SP-II, through filler tube,
until COLD level is reached on dipstick.
3) Start engine and allow to idle for 2 minutes. Shift
transaxle to each position, ending in Neutral. Add sufficient fluid to
reach lower mark. After reaching normal operating temperature, fluid
should be between upper and lower marks of HOT range on dipstick.
Transmission (Montero)
1) Remove drain plug (if equipped) from transmission pan, an\
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allow fluid to drain. On models without drain plug, oil pan must be

removed to drain fluid. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS . Clean oil pan, replace
gasket, and install oil pan. Tighten oil pan bolts and drain plug to
specification. See TORQUE SPECIFICATIONS . Ensure dipstick hole area is
clean. Fill transmission with Dexron-II ATF, through filler tube,
until COLD level is reached on dipstick. Start engine, and allow to
idle for 2 minutes.
3) Shift transmission into each position, ending in Neutral.
Check fluid level with engine running at idle. If necessary, add
sufficient fluid to bring level to lower mark of dipstick. Recheck
fluid level after transmission is at normal operating temperature.
Transfer Case
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. Lubricant level should be
at bottom of fill hole on side of transfer case.
ADJUSTMENTS
KICKDOWN SERVO
Eclipse, Galant & 3000 GT
1) Remove all dirt and grease around kickdown servo switch.
Remove snap ring and kickdown servo switch.
2) To prevent servo piston from turning, install Adapter
(MD998915) and Kickdown Servo Wrench (MD998918) so tab of wrench
engages with notch of piston. See Fig. 1.
CAUTION: DO NOT push servo piston inward while installing adapter and
servo wrench. Install adapter in brake pressure port by hand
ONLY. DO NOT use wrench to tighten adapter.
Fig. 1: Adjusting Kickdown Servo (Eclipse, Galant & 3000 GT)
Courtesy of Mitsubishi Motor Sales of America.
3) Loosen lock nut to "V" channel of adjuster rod. Tighten
inner section of Kickdown Service Adjustment Assembly (MD998916) until\

it contacts lock nut. See Fig. 1.
4) Install outer section of kickdown service adjustment
assembly on lock nut. Rotate outer section to left and inner section
to right to contact lock nut with inner section.
5) Using an INCH-lb. torque wrench on inner section, tighten
inner section to 89 INCH lbs. (10 N.m), and then loosen inner section.\
Tighten inner section to 44 INCH lbs. (5 N.m).
CAUTION: Before tightening lock nut with torque wrench, tighten it by
hand until it contacts piston. If torque wrench is used
initially, lock nut and adjustment rod may rotate together.
6) Back off outer section 2-2 1/4 turns. Rotate outer section
to right and inner section to left until inner section is free of lock
nut. Tighten lock nut by hand until it contacts piston. Using torque
wrench, tighten lock nut to 18-23 ft. lbs. (25-32 N.m).
7) Remove adapter and kickdown servo wrench. Install new "O"
ring in groove around switch. Install switch and snap ring.
SHIFT LINKAGE
Except Montero
1) Ensure shift and transaxle/transmission levers are both in
Neutral position. Loosen adjusting nut on control cable. See Fig. 2.
Loosen park/neutral position switch body bolts. Rotate park/neutral
position switch until hole in end of transmission manual control lever
is aligned with hole (cross section A-A) in flange of park/neutral
position switch body. Tighten park/neutral position switch body bolts.
Ensure holes in park/neutral position switch flange and transmission
manual control lever stay aligned.
2) Gently pull control cable from dust cover. Make sure shift
lever is still in Neutral. Tighten adjusting nut. Check
transaxle/transmission operation through all ranges. Readjust control
cable if necessary.
Fig. 2: Adjusting Shift Cable (Except Montero)
Courtesy of Mitsubishi Motor Sales of America.
Montero
Ensure shift and transmission levers are both in Neutral