1998 MITSUBISHI MONTERO 4WD
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CLUTCH RELEASE CYLINDER
Disassembly
Remove valve plate and spring. See Fig. 7. Remove push rod
and boot. Cover piston assembly opening with a rag. Slowly apply air
pressure to hydraulic line opening to force piston from body.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. To
reassemble, reverse disassembly procedure. Ensure piston moves freely
in bore.
Fig. 7: Exploded View Of Clutch Release Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Clutch Pedal Position Switch Adjusting Nut Or Bolt ......... 10 (13)\
Bellhousing-To-Engine Mounting Bolt
Montero
10 x 40 mm ............................................. 26 (36)\
10 x 55 mm ............................................. 22 (31)\
12 x 40 mm ............................................. 54 (75)\
12 x 55 mm ............................................. 65 (90)\
Montero Sport
2WD .................................................... 19 (26)\
4WD .................................................... 55 (75)\
Clutch Master Cylinder Mounting Nut ........................ 10 (13)\
Page 369 of 1501
DIFFERENTIAL & AXLE SHAFTS REAR
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Differentials & Axle Shafts - Rear Non-Integral
Montero, Montero Sport
DESCRIPTION
Rear axle features a rigid banjo-type housing with semi-
floating axle shafts. Differential consists of hypoid reduction gears
and straight bevel differential gears. Limited Slip Differential (LSD)\
is available on some models. Locking rear differential is available on
1997-98 Montero and 1998 Montero Sport. See DIFFERENTIAL LOCK - REAR
article.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS
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Application Ratio
Montero ..................................................... 4.27:1
Montero Sport
With Wide Fender
2WD ..................................................... 4.22:1
4WD ..................................................... 4.27:1
Without Wide Fender ....................................... 4.64:1
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LUBRICATION
CAPACITY
REAR AXLE GEAR OIL CAPACITY \
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Application Pts. (L)\
Montero .................................................. 6.8 (3.2)\
Montero Sport
Conventional & Locking ................................. 3.2 (1.5)\
Limited Slip ........................................... 5.5 (2.6)\
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FLUID TYPE
Conventional differentials use SAE 80W or SAE 90W API GL-5.
Limited slip differentials use Mitsubishi Gear Oil (8149630 EX), or
Mopar Gear Oil (4318058) and Mopar Friction Modifier (4318060).
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.
Page 470 of 1501
Door Lock Control Unit Behind left side of dash.
ELC 4-Speed Automatic Transmission
Control Module Behind left side of dash.
Engine Control Module (ECM) Behind right kick panel.
Keyless Entry Control Unit Behind right side quarter
panel.
Rear Differential Lock Control Unit Mounted on top of left rear
wheelwell.
SRS Air Bag Control Unit Behind center of dash.
Sun Roof Control Unit On center of roof, behind
sun roof.
Variable Shock Absorber Control Unit Behind left rear wheelwell,
behind quarter panel.
4WD Indicator Control Unit Behind center of dash.
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MOTORS
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Component Component Location \
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Blower Motor Behind right side of dash.
Condenser Fan Motor On left front of engine
compartment.
Fuel Pump In fuel tank.
Headlight Washer Motor Right side of engine
compartment, in washer fluid
reservoir.
Idle Air Control Motor On throttle body.
Motor Antenna Rear of right front wheelwell.
Rear Differential Lock Air Pump On left rear of vehicle.
Rear Washer Motor In rear of cargo area.
Rear Wiper Motor On center of tailgate.
Sun Roof Motor On center of roof, behind
sun roof.
Windshield Washer Motor Bottom of windshield washer
reservoir.
Windshield Wiper Motor On left side of firewall.
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SENDING UNITS & SENSORS
Page 474 of 1501
Center Differential Lock Operation
Detection Switch On transfer case.
Dual Pressure Switch On high pressure line, on
receiver-drier.
Engine Coolant Temperature Switch Top right front of engine.
Free Wheel Engage Switch Right side of engine
compartment.
High Range/Low Range Detection Switch On transfer case.
Low Range Operation Detection Switch On transfer case.
Oil Pressure Switch Lower left front of engine.
Parking Brake Switch At base of parking brake
lever.
Power Steering Pressure Switch On power steering pump.
Rear Differential Lock Detection
Switch Under rear of vehicle, on
differential.
Reed Switch Integral with speedometer.
Seat Belt Switch On driver-side seat belt
buckle.
Stoplight Switch On bracket, above brake pedal.
2WD/4WD Detection Switch On transfer case.
4WD Operation Detection Switch On transfer case.
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MISCELLANEOUS
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Component Component Location \
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Amplifier Under center console, below
floor.
Data Link Connector (DLC) Behind left side of dash,
near relay box.
Page 475 of 1501
Diode (Active Trac 4WD Circuit) Behind right side of dash,
taped to harness.
Diode (Door Light Circuit) Behind left side of dash,
taped to harness.
Page 945 of 1501
LOCKING HUBS
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Locking Hubs
Montero, Montero Sport
DESCRIPTION
Vehicles are equipped with an automatic locking clutch.
Locking clutch engages, providing full time AWD operation, when 4WD
(4H) is selected at transfer case, at speeds up to 62 MPH. Selecting
center differential lock position (4HLc or 4HLLc), while in AWD at 4
MPH or less, provides 4WD operation. Center differential lock
disengages when 4H or 2H is selected. Locking clutch disengages when
2H is selected.
REMOVAL & INSTALLATION
AUTOMATIC LOCKING HUBS
Removal & Installation
1) Remove right side inner shaft for automatic locking clutch
removal. See INNER SHAFT & BEARING in
DIFFERENTIAL & AXLE SHAFTS - FRONT article. With inner shaft removed,
remove locking clutch engage switch. See Fig. 1.
2) Remove 4 inner shaft tube-to-differential mounting bracket
bolts. Pivot differential mounting bracket. Remove 4 inner shaft tube-
to-differential carrier assembly mounting bolts. Pull inner shaft tube
and automatic locking clutch out of differential carrier assembly.
3) To install, reverse removal procedure. Tighten inner shaft
tube bolts to 65 ft. lbs. (90 N.m) and locking clutch engage switch to\
26 ft. lbs.(36 N.m).
Fig. 1: Identifying Automatic Locking Clutch Components
Courtesy of Mitsubishi Motor Sales of America.
OVERHAUL
Page 1020 of 1501
Pickup .......... 1996-97 ........... DS .............. NISSAN-5
Pulsar NX ....... 1989-90 ........... DS .............. NISSAN-6
Quest ........... 1997-98 ........... D/P ............. NISSAN-3
1996 ............. D/P ............. NISSAN-4
1994-95 ........... DS .............. NISSAN-5
Sentra .......... 1997-98 ........... D/P ............. NISSAN-3
1995-96 ........... D/P ............. NISSAN-4
1994 ............. DS .............. NISSAN-5
1993 ............. DS .............. NISSAN-6
200SX ........... 1997-98 ........... D/P ............. NISSAN-3
1995-96 ........... D/P ............. NISSAN-4
240SX ........... 1997-98 ........... D/P ............. NISSAN-3
1995-96 ........... D/P ............. NISSAN-4
300ZX ........... 1994-96 ........... D/P ............. NISSAN-4
1991-93 ........... DS .............. NISSAN-6
(1) - Location Definitions: D/P = Driver's & Passenger's Side,
DS = Driver's Side Only, SI = Side Impact.
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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - NISSAN-1 \
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Action Component or System
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Replace After
* Air Bag Module(s)
Deployment
* Control Unit, Diagnosis
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Inspect & If
* Crash Zone Sensor ( 1)
Damaged, Replace
* Instrument Panel
Component
* Passenger Deactivation Switch
(Even If Air
* Spiral Cable
Bag Did Not
* Steering Wheel
Deploy)
* Wiring Harnesses
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Comments
* If any components are damaged or bent, they
must be replaced.
* DO NOT attempt SRS wiring harness repairs.
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1) - 4WD only.
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INSPECTION PROCEDURES TABLE - NISSAN-2 \
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Action Component or System
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Replace After
* Air Bag Module(s)
Deployment
* Control Unit, Diagnosis
* Side Air Bag Module ( 1)
* Satellite Sensor ( 1)
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Inspect & If
* Center Pillar Inner ( 1)
Damaged, Replace
* Instrument Panel
Component
* Seat ( 1)
(Even If Air
* Spiral Cable
Bag Did Not
* Steering Wheel
Deploy)
* Wiring Harnesses
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Comments
* If any components are damaged or bent, they
must be replaced.
Page 1022 of 1501
(1) - Except Pathfinder and Pickup.
(
2) - 4WD Pickup only.
(
3) - Pathfinder only.
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INSPECTION PROCEDURES TABLE - NISSAN-6 \
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Action Component or System
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Replace After
* Air Bag Module(s)
Deployment
* Control Unit, Diagnosis
* Sensors In Affected Collision Area
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Inspect & If
* All Sensors Spiral Cable
Damaged, Replace
* Steering Wheel
Component
* Wiring Harnesses
(Even If Air
Bag Did Not
Deploy)
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Comments
* If any components are damaged or bent, they
must be replaced.
* DO NOT attempt SRS wiring harness repairs.
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SUBARU (1992-98)
AIR BAG APPLICATION
AIR BAG APPLICATION TABLE - SUBARU (1992-98) \
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Model Year (1) Location
Forester .............. 1998 ....................... D/P
Impreza ............. 1994-98 ...................... D/P
1993 ........................ DS
Legacy .............. 1995-98 ...................... D/P
1992-94 ....................... DS
SVX ................. 1994-97 ...................... D/P
1992-93 ....................... DS
( 1) - Location Definitions: D/P = Driver's & Passenger's
Side, DS = Driver's Side Only, SI = Side Impact.
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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - SUBARU (1992-98) \
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Action Component or System
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Replace After
* Air Bag Module(s)
Deployment
* Air Bag Control Module
* Front Impact Sensors ( 1)
* Side Air Bag Sensors ( 2)
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Inspect & If
* Air Bag Control Module
Damaged, Replace
* Combination Switch & Clockspring
Component
* Front Impact Sensors
(Even If Air
Bag Did Not
Deploy)