1998 MITSUBISHI MONTERO oil

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

STEERING SYSTEM - POWER RECIRCULATING BALL
1998 Mitsubishi Montero
1997-98 STEERING
Mitsubishi - Power Recirculating Ball
Montero, Montero Sport
DESCRIPTION & OPERATION
STEERING GEAR
The power steering gear displaces fluid to provide hydraulic
pressure assist while turning. A one-piece rack piston nut is geared
to cross shaft. Backlash is adjusted with an adjusting screw.
STEERING LINKAGE
Linkage consists of an idler arm, relay rod, steering
knuckles and adjustable tie rods. Components are connected by ball
joints. Linkage assembly is connected to steering gear by pitman arm.
LUBRICATION
FLUID TYPE
Recommended fluid type is Dexron-II ATF.
FLUID LEVEL CHECK
Place vehicle in level position. Start engine and let idle.
Turn steering wheel left and right. Replace fluid if it has bubbles or
has become White. Fluid level should be between MIN and MAX marks on
dipstick. Fill to proper level.
FLUID REPLACEMENT
CAUTION: DO NOT crank engine for more than 15-20 seconds at a time.
1) Remove reservoir cap. Disconnect return hose at reservoir.
Drain fluid. Disconnect coil high tension wire. Raise and support
vehicle.
2) Turn steering wheel lock-to-lock several times while
cranking engine to drain fluid from steering gear. Reconnect hose.
Fill power steering system with fluid. Bleed system. See
HYDRAULIC SYSTEM BLEEDING .
HYDRAULIC SYSTEM BLEEDING
CAUTION: DO NOT crank engine for more than 15-20 seconds at a time.
Add fluid as needed during procedure to prevent reservoir
level from dropping.
1) Ensure reservoir is filled before bleeding. Add fluid (if
necessary) during bleeding. Raise and support front of vehicle.
Disconnect coil high tension wire.
2) While cranking engine, turn steering wheel lock-to-lock 5
or 6 times. Lower vehicle. Connect coil wire. Start engine and let
idle. Turn steering wheel lock-to-lock until no more bubbles appear in
oil reservoir.

end dust cover. Coat lower edge of cup with packing sealer. Install
tie rod ends into adjusting sleeves.
2) Measure center-to-center distance between tie rod studs
for both tie rod assemblies. Adjust center-to-center distance to
specification. See TIE ROD INSTALLATION LENGTH table.
3) An equal number of threads should be visible on each side
of adjusting sleeve. Install tie rod ends in steering knuckle and
relay rod. Install tie rod end castle nuts and NEW cotter pins.
Tighten castle nuts to specification. See TORQUE SPECIFICATIONS.
Adjust toe-in. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article
in WHEEL ALIGNMENT section.
TIE ROD INSTALLATION LENGTH









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Application In. (mm)\
Montero .............................................. 12.05 (306.0)\
Montero Sport ........................................... 12.0 (305)\









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OVERHAUL
POWER STEERING GEAR
Disassembly
1) Scribe mating marks on pitman arm and cross shaft. Remove
pitman arm nut. Using a puller, remove pitman arm. Drain power
steering fluid. Remove side cover bolts. See Fig. 3. Loosen adjusting
bolt lock nut, and screw in adjusting bolt so side cover raises
slightly.
2) With mainshaft and cross shaft placed in straight-ahead
position, tap bottom of cross shaft with plastic hammer. Remove cross
shaft and side cover as an assembly. Remove side cover from cross
shaft by turning adjusting bolt.
3) Remove valve housing and rack piston as an assembly by
turning rack piston counterclockwise. See Fig. 3. Carefully remove
rack piston from mainshaft without losing balls inside rack piston.
4) Remove cross shaft oil seal from gearbox housing. Put rack
piston in soft jawed vise. Using Spanner Wrench (MB991367) and Pin Set\
(MB991394), remove lock nut. Remove mainshaft while applying pressure
to bearing race to prevent balls from falling out. Drive out bearing
and oil seal.
NOTE: DO NOT remove cross shaft "U" packing at rear of needle
bearing unless fluid leakage is found coming from adjusting
bolt threads. If leakage exists, replace "U" packing.

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.

2) Remove cam ring, vanes, shaft assembly and "O" rings.
Remove snap ring from shaft assembly. Remove collar, rotor and side
plate from shaft.
3) Pry oil seal out of housing. Remove pressure connector.
Remove flow control valve assembly, flow control spring and 2 "O"
rings. DO NOT disassemble flow control valve assembly.
Fig. 4: Exploded View Of Power Steering Pump
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Inspect pump shaft oil seal lip and bushing end for

damage. Inspect groove of rotor vane and cam surface for stepped wear.
Check vane for damage. Install vane into rotor groove. Measure
clearance between vane and rotor groove. If clearance exceeds .0024"
(.061 mm), replace entire assembly.
2) Check ring and rotor sides for damage. Replace entire
assembly if any damage is present. Check sliding surfaces of control
valve for obstructions. Replace parts as required. If control valve is
replaced, always use valve with same identification mark as one being
replaced. Check power steering fluid pressure.
Reassembly
1) Lubricate "O" rings and internal pump components with ATF
before reassembly. Install flow control valve spring and control valve
in housing.
2) Install and tighten pressure connector. Depress control
valve to check for smooth operation. Apply grease to lip of oil seal.
Install oil seal into pump body. Install pulley assembly into pump
body.
3) Install rotor to pulley assembly with punch mark at pump
cover side. Install snap ring. Lift rotor to ensure that snap ring is
in countersunk part of shaft. Align cam ring dowel holes and install
cam ring with punch mark on pump body side.
4) Apply transmission fluid to vanes, and install vanes onto
rotor with rounded edges outward. Install "O" ring, cam case and pump
cover. Install and tighten suction connector.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Adjusting Bolt Lock Nut .................................... 27 (37)\
Idler Arm Bracket-To-Frame Bolt & Nut
Montero ............................................ 40-47 (54-64)\
Montero Sport ............................................ 43 (59)\
Idler Arm-To-Bracket Lock Nut ............................. 101 (44)\
Oil Pump Cover Bolts ....................................... 15 (20)\
Pitman Arm-To-Cross Shaft Nut
Montero ........................................ 108-123 (146-176)\
Montero Sport .................................. 108-123 (147-167)\
Pressure Hose In-Line Fitting
Montero .................................................. 25 (34)\
Montero Sport ............................................ 16 (22)\
Relay Rod-To-Idler Arm Nut ................................. 33 (44)\
Relay Rod-To-Pitman Arm Nut ................................ 33 (44)\
Side Cover Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (50-64)\
Steering Gear Hose Fittings ................................ 11 (15)\
Steering Gear-To-Frame Bolts ......................... 40-47 (54-64)\
Tie Rod Adjusting Sleeve Lock Nuts ......................... 69 (93)\
Tie Rod End Castle Nuts .................................... 33 (44)\
Valve Housing Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (56-64)\
Valve Housing Lock Nut ......................................... ( 1)
( 1) - Tighten lock nut until it contacts bearing race.









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* STEERING UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS

the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
STEERING AND SUSPENSION
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
Steering and suspension are complex systems made up of a
variety of interdependent components. For proper vehicle handling,
ride, and tire wear, a thorough inspection is required whenever
suspension work is being performed.
Conditions listed assume that the problem has been isolated
to the specific component by proper testing procedures.
NOTE: When replacing steering and/or suspension components which
may affect an alignment angle, you are required to check
and adjust alignment as needed. Refer to the OEM
specifications.
CAUTION: DO NOT use ride height altering or load compensating
components, such as variable rate springs and coil over
shocks, on vehicles with height or load sensing
proportioning valve-equipped braking systems, unless
these components are original equipment.
AIR RIDE SUSPENSION
NOTE: Depending on the air suspension design, there are some
aftermarket products available to eliminate the air ride
suspension on certain vehicles. If the system has been
eliminated with one of these products, then no service is
suggested or required.
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
NOTE: This section covers the air spring portion of the
air shock or strut. For damping portion of shock
or strut conditions and procedures, refer to the
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
section.
AIR RIDE SUSPENSION - AIR SHOCK AND AIR STRUT INSPECTION









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Condition Code Procedure
Inner fabric of air bag
damaged ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Outer covering of air bag
is cracked to the extent
that inner fabric of air
bag is visible ......... 1 ............ Suggest replacement.









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AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRING VALVE INSPECTION








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Condition Code Procedure