1998 MITSUBISHI MONTERO ABS

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Condition Code Procedure
Tire diameter incorrect,
affecting ABS or TCS ... A ............ Require replacement.
Tire pressure incorrect,
affecting ABS or TCS ... A .. Require repair or replacement.
Tire size incorrect,
affecting ABS or TCS ... A ............ Require replacement.









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TOOTHED RINGS (TONE WHEEL)
NOTE: Copied from Drivetrain UIGs.
If the toothed ring requires replacement and cannot be
replaced as a separate component, replace the assembly of which the
ring is a part.
TOOTHED RING INSPECTION









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Condition Code Procedure
Alignment incorrect ..... B ............... Require repair or
replacement.
Bent .................... B ............ Require replacement.
Contaminated, affecting
performance ............. A ........ Require repair. Identify
and correct cause.
Cracked ................. B ............ Require replacement.
Loose ................... A ............. Require replacement
of worn parts.
Missing ................. C ............ Require replacement.
Number of teeth
incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.









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VACUUM BOOSTERS
VACUUM BOOSTER INSPECTION








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Condition Code Procedure
Applies too much assist
(oversensitive) ........ A ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Auxiliary vacuum pump
inoperative ............ A ........... ( 1) Require repair or
replacement.
Check valve grommet
deteriorated, affecting
performance ............ A .. Require replacement of grommet.

pressure at specified pressure range (split point). See
SPLIT POINT PRESSURE SPECIFICATIONS table.
SPLIT POINT PRESSURE SPECIFICATIONS









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Application psi (kg/cm)
Diamante .......................................... 312-383 (22-27)\
Eclipse
Without ABS ...................................... 320-391 (22-27)\
With ABS ......................................... 320-391 (22-27)\
Galant ............................................. 462-533 (33-38)\
Mirage
2-Door ........................................... 320-392 (22-26)\
4-Door ........................................... 391-463 (27-32)\
Montero Sport .................................................. ( 1)
( 1) - Information not available from manufacturer.









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3) Continue depressing brake pedal, and check readings on
pressure gauges. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS
table. If fluid pressures or split point are not within specification,
replace proportioning valve.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS









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Application/ Inlet Pressure (1) Outlet Pressure
Model psi (kg/cm) psi (kg/cm)
Diamante ................... 1138 (80) ........... 676-747 (48-53\
)
Eclipse
With ABS ................. 996 (69) ............ 569-640 (39-44\
)
Without ABS .............. 925 (61) ............ 462-533 (32-37\
)
Galant ..................... 996 (69) ................... 604 (43\
)
Mirage
2-Door ................... 1422 (98) ........... 566-680 (39-47\
)
4-Door ................... 1422 (98) ........... 619-733 (43-51\
)
3000GT
Hatchback ................ 906 (64) ............ 651-723 (46-51\
)
Convertible .............. 1117 (79) ........... 846-917 (60-65\
)
Montero Sport ................. ( 1) .......................... ( 1)
( 1) - Information is not available from manufacturer.









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REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
CAUTION: DO NOT remove or contaminate special grease coating on lock
pins.
Removal & Installation (Except 3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
lower lock pin or sleeve bolt. See Figs. 13-15. Lift caliper body
upward. Support caliper aside. Remove shims and pads from support
mounting. Remove pad clips.
2) If installing new pads, compress piston to bottom of bore.
Install retaining clips, pads and shims. Start engine and depress
brake pedal several times to expand caliper piston. Check brake fluid
level.

Fig. 10: Exploded View Of Parking Brake Assembly (Typical With Rear
Disc Brakes - Except Diamante)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Shoe-to-anchor spring must be installed correctly for proper
functioning of parking brakes.
Installation
1) To install, reverse removal procedure. When installing
shoe-to-anchor spring, ensure spring is installed correctly. When
installing adjuster, install left adjuster with adjusting bolt facing
vehicle front and right adjuster with adjusting bolt facing vehicle
rear.
2) On models with ABS, ensure gap between rotor teeth and
speed sensor pole piece is 0.008-0.039" (0.20-1.00 mm).
Removal (3000GT)
1) Raise and support vehicle. Remove rear wheel(s).
Disconnect rear speed sensor. Remove rear disc brake calipers and

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Removal & Installation (3000GT AWD Models)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). Remove caliper and rotor.
2) Remove 4 bolts and separate rear drive axle from hub
companion flange. Using Yoke Holder (MB990767), hold rear axle hub and\
remove axle nut at companion flange.
3) Using slide hammer and Hub Adapter (MB991354), remove axl\
e
shaft from knuckle. Place axle in hydraulic press. Using an
appropriate bearing splitter, remove ABS rotor (if equipped) and outer\
axle bearing.
4) Remove inner bearing and seal from axle. Using Bearing
Installer Handle (MB990938) and Adapter (MB990931), install bearing
and axle seal.
5) Using Installer (MB990799), install dust shield onto axle\
shaft. Using hydraulic press, install outer axle bearing onto axle
shaft so seal lip is facing towards axle shaft. Press on wheel speed
sensor rotor (if equipped) with groove on speed sensor rotor is facing\
towards axle shaft flange.
6) Install axle shaft assembly into knuckle and tighten axle
nut to 188-217 ft. lbs. (260-300 N.m.). To complete installation,
reverse removal procedure. Tighten bolts to specification.
OVERHAUL
NOTE: For exploded views of calipers, see Figs. 13 through 17. For
exploded view of master cylinder, see Fig. 18.
Fig. 13: Exploded View Of Single Piston Caliper Assembly (Except
Montero Sport)
Courtesy of Mitsubishi Motor Sales of America.

Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Drum Inside Diameter (Maximum) ........................... 9.1 (231\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter
With ABS .............................................. 1.0 (25.4)\
Without ABS ........................................... .93 (23.8)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\









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BRAKE SPECIFICATIONS (GALANT)








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Application In. (mm)\
Booster Pushrod Clearance
Single Booster ............................... .024-.031 (.60-.80)\
Tandem Booster ............................... .016-.024 (.40-.60)\
Disc Runout ............................................. .003 (.08)\
Disc Thickness (Minimum) ................................ .88 (22.4\
)
Drum Inside Diameter (Maximum) ........................... 9.1 (231\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\









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BRAKE SPECIFICATIONS (MIRAGE)








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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.033 (.65-.85)\
Disc Runout ........................................... .006 (.0024)\
Disc Thickness (Minimum) ................................ .65 (16.4\
)
Drum Inside Diameter (Maximum) ........................... 8.1 (206\
)
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ........................ .87 (22.22)\
Pad Lining Thickness (Minimum) ........................... .08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter ......................... .750 (19.1)\









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BRAKE SPECIFICATIONS (MONTERO)








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Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.035 (.65-.90)\
Disc Runout
Front ................................................. .004 (.10)\
Rear .................................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. 1.0 (25.4)\
Rear .................................................. .65 (16.4)\
Hub End Play ........................................... .0098 (.25)\
Master Cylinder Inside Diameter ........................ .937 (23.8)\
Pad Lining Thickness (Minimum)
Front ................................................. 1.08 (2.0)\
Rear ........................................................ (1)
Parking Brake Drum Diameter (Maximum) .................. 7.795 (198\
)

AXLE SHAFT R & I
Removal (Montero & Montero Sport)
Block front wheels. Raise and support rear axle housing.
Remove brake caliper and rotor. See Fig. 3. Remove parking brake cable
attaching bolts. Remove connection for parking brake cable end from
rear brake assembly. Remove ABS speed sensor (if equipped). Unbolt
backing plate with bearing housing from rear axle housing. Using
Puller (MB990241) and Slide Hammer (MB990211), remove axle assembly.\
DO NOT damage oil seal. Remove "O" ring. Replace if necessary.
Installation
Install NEW oil seal in axle housing as needed. To install
axle assembly, reverse removal procedure.
Fig. 3: Exploded View Of Typical Axle Shaft
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Insert new "O" ring and shim of .04" (1.0 mm) thickness

DIFFERENTIAL LOCK - REAR
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Rear Differential Lock
Montero, Montero Sport
DESCRIPTION & OPERATION
The rear differential lock system is designed to be used only
when low-speed wheel spin occurs in a ditch, or on a slippery or
uneven surface. The indicator light will blink when switch is turned
on as system completes locking operation. After the differential is
locked, the light will stop blinking and remain on.
The rear differential lock system will not lock with vehicle
in 4H or 2H position, and if vehicle speed is greater than 7 MPH.
Vehicle speed should be maintained at less than 12 MPH during rear
differential lock operation.
NOTE: The Anti-lock Brake System (ABS) does not operate when the
rear differential is locked. It is normal for the ABS
warning light to be on at this time.
COMPONENT LOCATIONS
Rear Differential Lock Air Pump
Air pump is located under left side of rear seat.
Rear Differential Lock Control Unit
Control unit is located under left side lower quarter trim
panel in rear compartment.
Rear Differential Lock Switch
Lock switch is located on lower center of instrument panel,
below radio.
Rear Differential Lock Detection Switch
Lock detection switch is located on rear differential
carrier.
TROUBLE SHOOTING
INDICATOR LIGHT FLASHES WHEN LOCK SWITCH IS TURNED ON
If vehicle speed is greater than 7 MPH, reduce speed to less
than 3 MPH. If vehicle speed is less than 7 MPH, rotate steering wheel
to right and left to reset light.
INDICATOR LIGHT FLASHES WHEN LOCK SWITCH IS TURNED OFF
If indicator flashes after lock switch is turned off, depress
and release accelerator several times while driving straight ahead to
reset light.
TESTING
REAR DIFFERENTIAL LOCK AIR PUMP

VEHICLE SPEED SENSORS
VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE
WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS
YOKES AND SLIP YOKES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection were recently published.
Further, revisions to all of these inspection communication standards
are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method