1998 MITSUBISHI MONTERO 4WD

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Page 154 of 1501

MITSUBISHI MONTERO 1998 Service Manual when transfer case is in 4WD low-lock range.
Fig. 1: Locating Transmission Control Module (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 2: Locating Transmission Control Module (Monte

Page 164 of 1501

MITSUBISHI MONTERO 1998 Service Manual If DTC 51 is set also, go to DTC 51: 1ST GEAR RATIO SIGNAL
INCORRECT test. If DTC 51 is not set, check overdrive brake for a
mechanical failure. See OVERDRIVE BRAKE in MITSUBISHI R4AW3 & V4AW

If DTC 51 is set also, go to DTC 51: 1ST GEAR RATIO SIGNAL
INCORRECT test. If DTC 51 is not set, check overdrive brake for a
mechanical failure. See OVERDRIVE BRAKE in MITSUBISHI R4AW3 & V4AW3
OVERHAUL article.
SYMPTOM TROUBLE SHOOTING
NOTE: Check system using appropriate scan tool. See WIRING DIAGRAMS
for electrical schematics and COMPONENT TESTING.
COMMUNICATION WITH SCAN TOOL NOT POSSIBLE
If scan tool cannot communicate with TCM, check proper
connection with DLC. Check TCM power circuits, TCM ground circuits and
malfunctioning TCM.
SHIFT POINTS INCORRECT
If shift points are incorrect, check for DTCs. If no DTC is
present, check oil temperature sensor, pattern select switch, 4WD low
range detection switch and TCM for proper operation.
UPSHIFTS OCCUR SPONTANEOUSLY
If upshifting occurs spontaneously, check park/neutral
position switch, overdrive switch and TCM for proper operation.
TCC LOCK-UP MALFUNCTIONING
If TCC lock-up system is not operating properly, check torque
converter, valve body, lock-up switch and oil temperature switch.
COMPONENT TESTING
A/T FLUID TEMPERATURE SWITCH
1) Remove fluid temperature switch, located to rear of
neutral safety switch. Immerse switch in container of ATF up to top
threaded portion of switch. Using a DVOM, check continuity between
switch terminals. Continuity should not exist when fluid temperature
is 257
F (125C) or less.
2) When fluid is heated to 289-304F (143-151C), continuity
should exist. Replace switch if necessary. Apply thread sealant to
fluid temperature switch threads and install in transmission.
BRAKELIGHT SWITCH
1) Disconnect electrical connector from brakelight switch,
located near brake pedal. Using ohmmeter, ensure continuity exists
between terminal No. 2 (White/Red wire) and terminal No. 3 (Green
wire) with brake pedal released. Replace brakelight switch if
continuity does not exist. Continuity should not exist between
terminals No. 2 and No. 3 with brake pedal depressed.
2) If continuity does not exist, ensure brake pedal is
properly adjusted so brakelight switch has proper travel for switch
operation. If proper brakelight switch travel exists, replace
brakelight switch.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Page 167 of 1501

MITSUBISHI MONTERO 1998 Service Manual Using a screwdriver, remove pattern select switch from
console. Switch is located at rear of selector lever, to right of
emergency brake handle. Using a DVOM, check continuity between pattern

Page 169 of 1501

$MITSUBISHI MONTERO 1998 Service Manual \b�� \ ��\ ��\ �� \ ��\ �� \ ��\ �� 14 No. 1 Shift Solenoid In 1st$

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14 No. 1 Shift Solenoid In 1st Or 2nd Battery
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14 No. 1 Shift Solenoid In 3rd Or 4th Gear 0 Volts
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15 Power Supply Ignition ON Battery
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15 Power Supply Ignition OFF 0 Volts
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16 No. 2 Shift Solenoid In 2nd Or 3rd Gear Battery
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16 No. 2 Shift Solenoid In 1st Or 4th Gear 0 Volts
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17 Diagnostic Test Mode Not Specified Not Specified
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18 Diagnostic Output Scan Tool Not Battery

Connected
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21 Oil Temp Warning Lamp Normal Temp. Range 0 Volts
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21 Oil Temp Warning Lamp For 5 Seconds After Battery

Ign. Is On
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22 Oil Temp Sensor Temp @ 248F (120C) About 1.9
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22 Oil Temp Sensor Temp @ 302F (150C) About 1.1
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23 4WD Low Range Switch 4WD Lever In 4H-Lock Battery
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23 4WD Low Range Switch 4WD Lever In 4L-Lock 0 Volts
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24 Neutral Safety Switch In "R" Position Battery
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24 Neutral Safety Switch Except In "R" 0 Volts
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25 Ground Engine Idling 0 Volts
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26 Ground Engine Idling 0 Volts
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31 Neutral Safety Switch In "L" Position Battery
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31 Neutral Safety Switch Except In "L" 0 Volts
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32 Neutral Safety Switch In "N" Position Battery
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32 Neutral Safety Switch Except In "N" 0 Volts
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34 Power Mode Power Mode Selected Battery
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34 4WD Detection Switch 2WD 4 Volts Or

Montero Greater
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34 4WD Detection Switch 4WD 0-1 Volts

Montero
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34 Free Wheel 2WD 4 Volts Or

Montero Engage Switch Greater

Sport
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34 Free Wheel 4WD 0 Volts

Montero Engage Switch

Sport
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Page 228 of 1501

MITSUBISHI MONTERO 1998 Service Manual Removal & Installation (3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
clip, brake pad retaining pins and spring. See Fig. 17. Remove shims
and pads from cali

Removal & Installation (3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
clip, brake pad retaining pins and spring. See Fig. 17. Remove shims
and pads from caliper. Keep track of location of shims for reassembly.
2) Compress caliper pistons fully in bores. Install shims on
brake pads. Install brake pads. Install spring clip, pad retaining
pins and clip. Start engine and depress brake pedal several times to
expand caliper piston. Check brake fluid level.
FRONT BRAKE CALIPER
Removal
Raise and support vehicle. Remove front wheels. Remove hose
clip from brake hose mount (if equipped). Disconnect brake hose from
caliper. Remove upper and lower caliper-to-steering knuckle bolts.
Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Bleed brake system. See
BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal & Installation (Except Montero & Montero Sport)
Raise vehicle, and remove wheel(s). Remove caliper. See
FRONT BRAKE CALIPER . Slide rotor off hub. To install, reverse removal
procedure.
Removal (Montero & Montero Sport)
Raise and support vehicle. Remove brake caliper. See
FRONT BRAKE CALIPER . On 4WD, remove Remove bearing grease cap, snap
ring, shim, 6 bolts and drive flange from axle shaft. On 2WD remove 6
bolts and hub cover. Remove screw(s) from lock washer. Remove lock
washer. Remove lock nut using Lock Nut Wrench (MB990954). Remove hub
assembly. Place match marks on rotor and hub. Remove rotor from front
hub.
Installation
1) Install rotor on hub. Service wheel bearings and seals as
necessary. Install front hub assembly. Install lock nut, and tighten
it to 119 ft. lbs. (165 N.m). Loosen lock nut, and retighten it to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Install lock washer
and screw(s).
2) On 2WD, reverse removal procedure for remaining
components. On 4WD, install drive flange, shim and snap ring. Using
feeler gauge, check axle shaft-to-hub clearance. Clearance should be
0.016-0.028" (0.41-0.71 mm). Use appropriate shim to obtain correct
clearance. Shim is located behind snap ring on end of axle shaft.
Recheck clearance if necessary. Install remaining components.
PARKING BRAKE SHOES
Removal & Installation (Diamante)
1) Raise and support vehicle. Remove rear wheels. Remove rear
disc brake caliper and rotor. If rotor removal is difficult, rotate
rotor until hole in rotor is upward. Back-off brake shoe adjustment
with a flat blade screwdriver through hole in rotor.
2) Disconnect rear speed sensor. See Fig. 9. Remove 4 bolts
and hub. Remove screw and shoe hold-down spring. Remove shoe. To
install, reverse removal procedure. Adjust brake shoe by turning
adjuster star wheel.

Page 250 of 1501

$MITSUBISHI MONTERO 1998 Service Manual (5) - Use Platinum spark plugs only.��\ ��\ ��\ ��\ ��\ ��\ �� REPLACEMENT INTERVALS TABLE (MON$

(5) - Use Platinum spark plugs only.\
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REPLACEMENT INTERVALS TABLE (MONTERO SPORT)\
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Component Miles
Air Filter ........................................ 30,000
Automatic Transmission
Except 4WD ......................................... ( 1)
4WD ............................................. 30,000
Axle Fluid ( 2) .................................... 30,000
Coolant ........................................... 30,000
Oil ................................................. 7500
Oil Filter .................................... ( 3) 15,000
Spark Plugs ( 4) ................................... 60,000
Spark Plug Wires .................................. 60,000
Timing Belt ....................................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Limited-slip differential.
( 3) - Replace oil filter at oil change if annual mileage is
less than 7500 miles.
( 4) - Use Platinum spark plugs only.
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REPLACEMENT INTERVALS TABLE (3000GT)\
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Component Miles
Air Filter ........................................ 30,000
Automatic Transaxle Fluid ............................ ( 1)
Coolant ........................................... 30,000
Oil
Non-Turbo ......................................... 7500
Turbo ............................................. 5000
Oil Filter
Non-Turbo ....................................... 15,000
Turbo ........................................... 10,000
Spark Plugs
Except Platinum ................................. 30,000
Platinum ........................................ 60,000
Spark Plug Wires ( 2) .............................. 60,000
Timing Belt ....................................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Except vehicles equipped with Federal Emissions.
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BELT ADJUSTMENT TABLE\
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( 1) Deflection ( 1) Deflection
Application New Belt - In. (mm) Used Belt - In. (mm\
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Diamante
Generator & A/C .... .24-.28 (6.0-7.2) ....... .32-.37 (8.2-9.3\
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P/S ................ .33-.37 (8.4-9.3) ..... .46-.52 (11.7-13.4\
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Eclipse
2.0L Non-Turbo

Page 261 of 1501

MITSUBISHI MONTERO 1998 Service Manual release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert a clutch alignment tool to prevent
pressure plate and clutch disc from dropping. Loosen pressure plate
bolts gradually in a crisscross pattern to avoid warping pressure
plate flange during removal. Remove pressure plate and clutch disc.
See Fig. 3 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

Page 263 of 1501

MITSUBISHI MONTERO 1998 Service Manual Apply a very light coating of grease to input shaft splines. DO NOT
allow grease or dirt on clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedu

Apply a very light coating of grease to input shaft splines. DO NOT
allow grease or dirt on clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
CLUTCH RELEASE BEARING & RELEASE FORK
Removal (2WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
clips, release bearing and carrier. Use a punch to remove shift arm
spring pin and release lever assembly. Remove shift arm, felt packing
and 2 return springs. See Fig. 5.
2) Ensure release bearing turns freely and smoothly under
light load. Replace bearing if noise, roughness or dryness is present.
DO NOT clean bearing in solvent. Use shop towel or compressed air
only.
Installation
1) Insert lever and shaft into left side of transmission
case. Place shift arm, felt packing and return springs on shaft
assembly. Apply grease to inside of bushing and oil seal lips. Apply
oil to felt packing.
2) Align shift arm pin and control shaft pin holes. Drive
spring pins into position, with slit area upward. Reverse removal
procedure to complete installation. Check pedal height and free play.
Adjust if necessary. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS.
Removal (4WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
spring or clips, and remove release bearing.
2) Slide release fork toward outside of transmission and
disengage from fulcrum ball. DO NOT slide release fork toward inside
of case, or damage to fulcrum ball clip will result. Remove release
fork boot.
Installation
To install, reverse removal procedure. Apply grease to
fulcrum ball contact area of release fork before installing. Fill
groove of release bearing inside diameter with grease before
installing. See Fig. 5.

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