1998 MITSUBISHI MONTERO boot

TIE ROD END (INNER AND OUTER) INSPECTION








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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace tie rod end.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace tie rod end.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace tie rod end.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace tie rod end.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
tie rod end.
Adjusting sleeve bent ... B ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve clamps
out of position ........ B ................. Require repair.
Adjusting sleeve
corroded, affecting
structural integrity ... A ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve
missing ................ C ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve
seized ................. A ........... (1) Require repair or
replacement.
Adjusting sleeve
threads damaged ........ A ... Require repair or replacement
of sleeve or tie rod end.
Adjusting sleeve
threads stripped
(threads missing) ...... A ... Require replacement of sleeve
or tie rod end.
Binding ................. A .......... ( 2) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 3) Suggest replacement.
Grease boot missing ..... 2 ........ ( 4) Suggest replacement.
Grease boot torn ........ 2 ........ ( 5) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ......... ( 4) Suggest replacement
of seal.

Grease seal torn ........ 2 ......... (5) Suggest replacement
of seal.
Greaseable tie rod end
won't take grease ...... 2 ...... ( 6) Suggest replacement of
grease fitting.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 7) Suggest replacement.
Looseness exceeds
manufacturer's
specifications ......... B ............ Require replacement.
Looseness that is
excessive .............. B ..... ( 7)( 8) Require replacement.
Nut on stud loose ....... A ........... ( 9) Require repair or
replacement of nut.
Seized .................. A ............. Require replacement
Stud bent ............... B ....... ( 10) Require replacement.
Stud broken ............. A ....... ( 10) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ....... ( 10) Require replacement.
( 1) - Only required if toe needs to be adjusted.
( 2) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 3) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 5) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 6) - If greaseable tie rod end will not take grease after
replacing the grease fitting, suggest replacement of
tie rod end.
( 7) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 8) - Excessive looseness is defined as being significant enough
to affect vehicle handling or structural integrity.
( 9) - Check for bent stud or damaged taper hole.
( 10 ) - Check for damaged taper hole.









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TRACK BARS
TRACK BAR INSPECTION








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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace track bar.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace track bar.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace track bar.
Attaching hardware

threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace track bar.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
track bar.
Bent .................... B ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Grease boot cracked ..... 2 ........ (1) Suggest replacement.
Grease boot missing ..... 2 ........ ( 2) Suggest replacement.
Grease boot torn ........ 2 ........ ( 3) Suggest replacement.
Holes distorted ......... A ............ Require replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 4) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 4)( 5) Require replacement.
Nut on stud loose ....... A ........... ( 6) Require repair or
replacement of nut.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 2) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 4) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 5) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural integrity.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.









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TRAILING ARMS
TRAILING ARM INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace trailing arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;

threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Dust boot missing ....... 2 ........ (1) Suggest replacement.
Dust boot split ......... 2 ........ ( 1) Suggest replacement.
Dust boot torn .......... 2 ........ ( 1) Suggest replacement.
Housing cracked ......... A ............ Require replacement.
Lead routing incorrect .. B .. Require rerouting according to
vehicle manufacturer's
specifications.
Loose ................... B ... Require adjustment to vehicle
manufacturer's specifications.
Missing ................. C ............ Require replacement.
Output signal incorrect . A .. Require repair or replacement.
Wire lead damaged ....... A .. Require repair or replacement.
( 1) - This condition can lead to damage of the sliding magnet,
which, in turn, causes premature sensor failure.









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AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - MODULE INSPECTION








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Condition Code Procedure
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Housing cracked ......... 2 .. Suggest repair or replacement.
Inoperative ............. A ............ Require replacement.
Missing ................. C ............ Require replacement.









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AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - RELAY (COMPRESSOR) INSPECTION








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Condition Code Procedure
Housing cracked ......... 2 ........ ( 1) Suggest replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
( 1) - If moisture enters the relay, it can reduce life
expectancy or impair function.









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AIR RIDE SUSPENSION - SWITCHES (ON/OFF)

previously diagnosed by the "perceptible movement"
standard. Before requiring or suggesting any parts be
replaced based on "perceptible movement," consult your
repair manual to determine if OEM specifications exist.
You are not required to replace ball joints in axle sets.
However, when replacing a ball joint due to wear exceeding
manufacturer's specification, you may suggest replacement of the other
ball joint if its measurement shows it is close to the end of its
useful life, for preventive maintenance.
BALL JOINT INSPECTION









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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace ball joint.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace ball joint.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace ball joint.
Attaching hardware
incorrect ............... A .......... Require replacement of
incorrect part if available;
otherwise, replace ball joint.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace ball joint.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace ball joint.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads if
available; otherwise, replace
ball joint.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
ball joint.
Binding ................. A .......... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Greaseable ball joint will

not take grease ........ 2 ...... (5) Suggest replacement of
grease fitting.
Nut on ball joint loose . A ........... ( 6) Require repair or
replacement.
Pre-load adjustment
incorrect .............. B .. Require repair or replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease ball joint. If problem persists
or joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
ball joint and will accelerate wear.
( 5) - If the greaseable ball joint still will not take grease
after replacing the grease fitting, suggest replacement
of ball joint.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.









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BUSHINGS
BUSHING INSPECTION








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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace bushing.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace bushing.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace bushing.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part if available;
otherwise, replace bushing.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace bushing.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace bushing.
Attaching hardware
threads damaged ........ A ... Require repair or replacement

available; otherwise, replace
center link.
Bent .................... B ............ Require replacement.
Binding ................. A ........... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ ( 3) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 5) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 5)( 6) Require replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Stud loose in
taper hole ............. A ........... ( 7) Require repair or
replacement.
Taper hole elongated .... A ........ ( 8) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
joint and will accelerate wear.
( 5) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 6) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural
integrity.
( 7) - Check for damaged taper hole.
( 8) - Check for damaged stud.









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CONTROL ARM SHAFTS
CONTROL ARM SHAFT INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken

if available; otherwise,
replace control arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
control arm.
Bent .................... B ............ Require replacement.
Bushing hole oversized .. B ............ Require replacement.
Ball joint hole oversized
(loose interference or
press fit) ............. B .......... (1) Further inspection
required.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Holes distorted ......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - If oversized ball joint is available, require
replacement of ball joint. If oversized ball joint
is not available, require replacement of control arm.









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DRAG LINKS
DRAG LINK INSPECTION








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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace drag link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace drag link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace drag link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace drag link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
drag link.
Bent .................... B ............ Require replacement.
Binding ................. A .......... ( 1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.