1998 MITSUBISHI MONTERO boot

tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Pack proper amount of grease in BJ and BJ boot. See
CV JOINT GREASE CAPACITY table. Boot bands must be installed so lever
is pulled toward rear of vehicle when band is tightened.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage. Apply
proper amount of grease to outer DOJ race. See
CV JOINT GREASE CAPACITY table. Install shaft into DOJ outer race.
Install circlip.
4) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between center line of boot
bands. Distance should be 3.03-3.27" (76.9-83.0 mm). This distance is
necessary to control air in DOJ boot. Tighten boot bands. Install boot
protector and band. Install dust cover on shaft.
CV JOINT GREASE CAPACITY









\









\









\









\









\









\









\







Application ( 1) Ozs. (g)
BJ Boot & Joint
Montero ................................................ 4.6 (130)\
Montero Sport .......................................... 4.2 (120)\
DOJ Boot & Joint
Montero ................................................ 3.5 (100)\
Montero Sport .......................................... 4.9 (140)\
( 1) - Apply 1/2 of the amount of grease specified to joint, the other
half to inside of CV boot.









\









\









\









\









\









\









\







DIFFERENTIAL ASSEMBLY
Disassembly
1) Remove differential carrier from vehicle. See
DIFFERENTIAL CARRIER ASSEMBLY under REMOVAL & INSTALLATION. Remove
cover. Mark bearing caps for reassembly reference. Remove bearing
caps. Remove differential case assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components
must be installed in original location.
2) Using bearing puller, remove differential case side
bearings. Loosen ring gear retaining bolts in diagonal sequence.
Remove ring gear. Remove drive pinion shaft lock pin from ring gear
side. Remove pinion shaft and pinion gears. Remove side gears and
thrust spacers.
Drive Pinion Removal
Remove pinion flange nut. Scribe alignment mark on pinion
companion flange and drive pinion. Remove flange. Using soft-faced
hammer, drive out pinion. Remove rear bearing and oil seal from
carrier. Remove rear adjusting shim from pinion. See Fig. 1. Press
front bearing from pinion. Remove front adjusting shim and spacer from
pinion.
Cleaning & Inspection
Use cleaning solvent to rinse gears and components. Check
bearings for wear or discoloration. Check gear carrier for cracks or
damage. Check pinion, side gear and flange splines for excessive wear.

* DRIVETRAIN SYSTEMS UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS

CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Cover gasket distorted .. A .... Require replacement of cover
gasket.
Cover gasket gummy ...... A .... Require replacement of cover
gasket.
Cylinder leaking fluid
from rear of bore ...... A .. Require repair or replacement.
Cylinder leaking fluid
internally ............. A ............ Require replacement.
Dust boot missing ....... C ..... Require replacement of dust
boot.
Dust boot punctured ..... A ..... Require replacement of dust
boot.
Dust boot torn .......... A ..... Require replacement of dust
boot.
Fluid level incorrect ... B . Require fluid level adjustment.
Housing damaged, affecting
performance ............ A .. Require repair or replacement.
Master cylinder has
residue in reservoir
(make parallel w/brakes
when they are done) .... 2 .......... ( 1) Further inspection
required.
Threads damaged ......... A ...... Require repair replacement
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - DO NOT replace master cylinder unless it exhibits
conditions listed for replacement. You may suggest fluid
change according to OEM service intervals.









\









\









\









\









\









\









\


CLUTCH PEDALS
CLUTCH PEDAL INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .......... Require replacement of
pedal pad.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.









\









\









\









\









\









\









\


CLUTCH PIVOTS
CLUTCH PIVOT INSPECTION








\









\









\









\









\









\









\

Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Clamp corroded, not
reusable ............... 1 ............ Suggest replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Corroded, not affecting
structural integrity ... .. ........ No service suggested or
required.
Cracked ................. A .. Require repair or replacement.
Fitting type incorrect
(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged to
the extent that the inner
fabric is visible ...... A ............ Require replacement.
Protective sleeves
damaged ................ 2 . Suggest replacement of sleeves.
Protective sleeves
missing ................ C . Require replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Routed incorrectly ...... 2 ................. Require repair.
Swollen ................. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Type incorrect .......... 1 .. Suggest repair or replacement.









\









\









\









\









\









\









\


COOLERS
See TRANSMISSION COOLERS .
CV JOINTS
CV JOINT INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Bearing, bushing or seal
surface worn, affecting
performance ............ A .. Require repair or replacement.
Boot clamp broken ....... A ... Require repair or replacement
of clamp.
Boot clamp loose ........ A ... Require repair or replacement
of clamp.
Boot clamp missing ...... C ... Require repair or replacement
of clamp.
Boot leaking ............ A . Require replacement of CV boot.
Boot surface cracked,

not leaking ............ 2 . Suggest replacement of CV boot.
Cage broken ............. A ... Require repair or replacement
of CV joint.
Housing damaged to the
extent that it no longer
performs its intended
function ............... A ........... (1) Require repair or
replacement of CV joint.
Housing worn to the extent
that it no longer performs
its intended function .. A ........... ( 1) Require repair or
replacement of CV joint.
Holes elongated ......... A ............ Require replacement.
Internal parts binding .. A .. Require repair or replacement.
Internal parts worn ..... A .. Require repair or replacement.
Lubricant missing ....... C ... Require cleaning, inspection,
and repacking of CV joint.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Housing assembly may appear blue in color from normal
manufacturing process of heat-treating the housing.









\









\









\









\









\









\









\


DIP STICK TUBES
DIP STICK TUBE INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Broken .................. A .. Require repair or replacement.
Checkball missing ....... C .. Suggest repair or replacement.
Cracked ................. A .. Require repair or replacement.
Hold down bracket
broken ................. A .. Require repair or replacement.
Hold down bracket
missing ................ C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.









\









\









\









\









\









\









\


DIP STICKS (FLUID LEVEL INDICATORS)
DIP STICK (FLUID LEVEL INDICATOR) INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Compressed .............. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Modified ................ A ............ Require replacement.
Stretched ............... A .. Require repair or replacement.









\









\









\









\









\









\









\


DOWEL PINS, GUIDES AND PILOT HOLES
DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION








\









\









\









\









\









\









\

Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Distorted ............... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Positioned incorrectly .. B .. Require repair or replacement.
Stepped ................. A .. Require repair or replacement.
Worn to the extent that it
no longer performs its
intended function ...... A .. Require repair or replacement.









\









\









\









\









\









\









\


DRIVE SHAFT FLANGES
See COMPANION FLANGES .
DRIVE SHAFTS AND HALF SHAFTS
DRIVE SHAFT AND HALF SHAFT INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Balance weight missing .. C .. Require repair or replacement.
Bearing cap bore
distorted .............. A .. Require repair or replacement.
Bent .................... A ............ Require replacement.
Bolt holes elongated .... A .. Require repair or replacement.
Bushing or seal surface
worn, affecting
performance ............ A .. Require repair or replacement.
Leaking through soft yoke
plug ................... A ... Require repair or replacement
of soft yoke plug.
Out of balance .......... A .. Require repair or replacement.
Retainer strap bent ..... A .......... Require replacement of
retainer strap.
Slip yoke broken ........ A ............ Require replacement.
Splines worn, affecting
performance ............ A ............ Require replacement.
Splines worn close to
the end of their
useful life ............ 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
U-bolt damaged, affecting
performance ............ A . Require replacement of U-bolts.
Yoke damaged, affecting
performance ............ A .. Require repair or replacement.









\









\









\









\









\









\









\


DUST BOOTS
NOTE: Does not include CV boots.
DUST BOOT INSPECTION









\









\









\









\









\









\









\


Condition Code Procedure
Cracked, not leaking .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.

CLUTCH PEDAL POSITION SWITCHES
COLD START INJECTORS
CONNECTORS
COOLANT
COOLANT RECOVERY TANKS
COOLING FAN MOTOR MODULES
COOLING FAN MOTOR RELAYS AND MODULES
COOLING FAN MOTOR RESISTORS
COOLING FAN MOTOR SENSORS AND SWITCHES
COOLING FAN MOTOR SWITCHES
COOLING FAN MOTORS
CRANKSHAFT POSITION SENSORS
DECEL VALVES
DEFLECTORS
DIP STICKS AND TUBES
DIP STICK TUBES
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR BOOTS AND SHIELDS
DISTRIBUTOR CAPS
DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR ROTORS
DISTRIBUTOR SHIELDS
DISTRIBUTORS
EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)
EGR COOLERS
EGR EXHAUST MANIFOLD PASSAGES
EGR INTAKE AND EXHAUST MANIFOLD PASSAGES
EGR PLATES AND COOLERS
ELECTRONIC SPARK CONTROL MODULES
ELECTRONIC TRANSMISSION CONTROL DEVICES
ELECTRONIC TRANSMISSION FEEDBACK DEVICES
ENGINE COOLANT TEMPERATURE SENSORS
ENGINE COOLING SYSTEMS
ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)
ENGINE OIL
ENGINE OIL CANISTERS
ENGINE OIL COOLERS (EXTERNAL)
ENGINE OIL DRAIN PLUGS AND GASKETS
ENGINE OIL FILTERS AND CANISTERS
ENGINE OIL GASKETS
ENGINE OIL PRESSURE GAUGES (MECHANICAL)
EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES
EVAPORATIVE EMISSION (EVAP) CANISTERS
EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES
EXHAUST GAS RECIRCULATION DEVICES
EXHAUST GAS RECIRCULATION FEEDBACK DEVICES
EXPANSION PLUGS
FAN CONTROL SENSORS
FUEL
FUEL ACCUMULATORS AND DAMPERS
FUEL AND COLD START INJECTORS
FUEL DAMPERS
FUEL DELIVERY CHECK VALVES
FUEL DISTRIBUTORS (BOSCH CIS)
FUEL FILLER NECKS AND RESTRICTORS
FUEL FILTERS
FUEL INJECTORS
FUEL LEVEL SENDERS7
FUEL PRESSURE REGULATORS
FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL)
FUEL RAILS
FUEL RESTRICTORS

FUEL TANKS
GAS CAPS
GASKETS
GROMMETS (VALVE COVER)
HARMONIC DAMPERS
HEATER CONTROL VALVES
HEATER CORES
HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
HOSE CLAMPS
HOSE CONNECTORS
HOSE COUPLERS
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOUSINGS
IDLE AIR CONTROLS
IDLE SPEED CONTROL ACTUATORS
IGNITION BOOTS
IGNITION COIL TOWERS
IGNITION COILS
IGNITION CONTROL MODULES (ICM)
IGNITION SWITCHES
IGNITION TERMINALS
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
IN-TANK FUEL STRAINERS
INERTIA FUEL SHUT-OFF SWITCHES
INTAKE AIR TEMPERATURE SENSORS
INTAKE MANIFOLDS
INTERCOOLERS
KNOCK SENSORS
LIQUID VAPOR SEPARATORS
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS
MASS AIR FLOW (MAF) SENSORS
METAL AIR MANIFOLDS AND PIPES
METAL AIR PIPES
MIX CONTROL SOLENOIDS
MOTOR MOUNTS
O-RINGS, GASKETS, SEALS AND SPRING LOCKS
O2 SENSORS
OIL PRESSURE SENDING UNITS
OIL PUMP PICK-UP SCREENS
OIL PUMPS
PARK NEUTRAL POSITION SWITCHES
PCV BREATHER ELEMENTS
PCV ORIFICES
PCV VALVES
PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND
OPTICAL)
POWER STEERING PRESSURE SENSORS
POWERTRAIN CONTROL MODULES (PCM) AND PROM
POWERTRAIN CONTROL PROM
PRESSURIZED EXPANSION TANK CAPS
RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS
RADIATOR FAN BLADES
RADIATOR FAN CLUTCHES
RADIATORS
ROLL OVER VALVES
SEALING COMPOUNDS
SEALS
SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES
SENSORS AND ACTUATORS
SHROUDS, BAFFLES AND DEFLECTORS
SPARK PLUGS
SPRING LOCKS