1998 MITSUBISHI MONTERO brake

sensor headlight aiming USB fuel reserve load capacity wiper size

Page 235 of 1501

MITSUBISHI MONTERO 1998 Service Manual cavity and contact surfaces. Install oil seal using seal driver. Press
new oil seal into bearing case until it is flush with face of bearing
case. Install backing plate and bearing case.
2) A

cavity and contact surfaces. Install oil seal using seal driver. Press
new oil seal into bearing case until it is flush with face of bearing
case. Install backing plate and bearing case.
2) Apply grease to external surfaces of bearing outer race.
Press bearing outer race into bearing case. Install rear brake
assembly and bearing case. Pack bearing case and axle threads with
grease. Install new retainer ring and snap ring.
3) Using a feeler gauge, measure clearance between snap ring
and new retainer ring. Clearance should be less than 0.0065" (0.165
mm). If clearance exceeds specification, install a new selective snap
ring to bring clearance to specification. See SNAP RING THICKNESS
SPECIFICATION table.
SNAP RING THICKNESS SPECIFICATION
\
\
\
\
\
\
\

Thickness: In. (mm) Color\
0.060 (1.52) ................................................... Red\
0.067 (1.70) ................................................ Purple\
0.073 (1.85) .................................................. Blue\
0.079 (2.01) ................................................ Yellow\
0.085 (2.16) ............................................... Neutral\
\
\
\
\
\
\
\

4) Check condition of oil seal and replace as necessary.
Install axle shaft assembly into axle housing. Tighten bearing
retainer bolts to 65 ft. lbs (15 N.m.). To complete installation,
reverse removal procedure.
REAR AXLE HUB BEARINGS
NOTE: Rear hub bearings are not serviceable on FWD models.
Removal & Installation (FWD Models)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). On models with drum brakes, remove brake
drum and shoes. See REAR BRAKE DRUM & SHOES .
2) On models with disc brakes, remove caliper and rotor. On
all models, remove hub bolts or spindle nut and hub assembly. To
install, reverse removal procedure. Tighten hub bolts or spindle nut
to specification. See HUB TIGHTENING TORQUE table. Rotate brake drum
or disc to ensure free movement.
NOTE: Rear hub bearings are not serviceable on Eclipse AWD models.
Removal & Installation (Eclipse AWD)
1) Raise and support vehicle. Remove wheels. Remove wheel
speed sensor (if equipped). On models with drum brakes, remove brake
drum and shoes. See REAR BRAKE DRUM & SHOES .
2) On models with disc brakes, remove caliper and rotor. On
all models, remove axle nut. Remove 4 hub bolts and hub assembly. To
install, reverse removal procedure. Tighten hub bolts to
specification. See HUB TIGHTENING TORQUE table. Rotate brake drum or
disc to ensure free movement.
HUB TIGHTENING TORQUE
\
\
\
\
\
\
\

Application Ft. Lbs. (N.m)\
Hub Mounting Bolts ................................... 54-65 (74-85)\
Spindle Nut
Mirage ................................................. 127 (172)\
3000GT FWD ............................................. 170 (230)\

Page 241 of 1501

$MITSUBISHI MONTERO 1998 Service Manual Fig. 18: Exploded View Of Master Cylinder (Typical) Courtesy of Mitsubishi Motor Sales of America. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (DIAMANTE)��\ ��$

Page 242 of 1501

$MITSUBISHI MONTERO 1998 Service Manual Wheel Cylinder Bolt ........................................ 89 (10)\ ��\ ��\ ��\ ��\ ��\ ��\ ��$

Wheel Cylinder Bolt ........................................ 89 (10)\
\
\
\
\
\
\
\

TORQUE SPECIFICATIONS (GALANT)\
\
\
\
\
\
\

Application Ft. Lbs. (N.m)\
Brake Line Flare Nuts ...................................... 11 (15)\
Caliper Guide & Lock Pin Bolt .............................. 54 (73)\
Caliper Mounting Bolts ..................................... 66 (90)\
Rear Hub-To-Knuckle Nut .................................... 60 (81)\
Wheel Lug Nut ....................................... 67-81 (90-110)\
INCH Lbs. (N.m)
Master Cylinder Mounting Booster Nut ...................... 115 (13)\
Bleeder Screw ............................................... 71 (8)\
Wheel Cylinder Bolt ........................................ 89 (10)\
\
\
\
\
\
\
\

TORQUE SPECIFICATIONS (MIRAGE)\
\
\
\
\
\
\

Application Ft. Lbs. (N.m)\
Brake Line Flare Nuts ...................................... 11 (15)\
Caliper Guide Pin Bolt ..................................... 36 (49)\
Caliper Lock Pin Bolt ................................ 61-69 (83-93)\
Caliper Mounting Bolts .............................. 66-81 (90-110)\
Rear Wheel Bearing Nut ................................... 127 (172)\
Wheel Lug Nut ....................................... 67-81 (90-110)\
INCH Lbs. (N.m)
Master Cylinder Mounting Booster Nut ...................... 115 (13)\
Bleeder Screw ............................................... 71 (8)\
Wheel Cylinder Bolt ........................................ 89 (10)\
\
\
\
\
\
\
\

TORQUE SPECIFICATIONS (MONTERO)\
\
\
\
\
\
\

Application Ft. Lbs. (N.m)\
Brake Line Flare Nuts ...................................... 11 (15)\
Caliper Guide & Lock Pin Bolt
Front .................................................... 54 (73)\
Rear ..................................................... 32 (44)\
Caliper Mounting Bolt ...................................... 65 (88)\
Wheel Lug Nut ....................................... 72-87 (98-118)\
Rear Axle Bearing Retainer Nut ................... 145-173 (196-235)\
INCH Lbs. (N.m)
Master Cylinder Mounting Nut .............................. 115 (13)\
Bleeder Screw ............................................... 71 (8)\
\
\
\
\
\
\
\

TORQUE SPECIFICATIONS (MONTERO SPORT)\
\
\
\
\
\
\

Application Ft. Lbs. (N.m)\
Brake Line Flare Nuts ...................................... 11 (15)\
Caliper Guide & Lock Pin Bolt (Front) ...................... 54 (73\
)
Caliper Mounting Bolt

Page 243 of 1501

$MITSUBISHI MONTERO 1998 Service Manual Front .................................................... 66 (90)\ Rear .................................................... 94 (127)\ Wheel Lug Nut 15x6" Wheel .........................$

Front .................................................... 66 (90)\
Rear .................................................... 94 (127)\
Wheel Lug Nut
15x6" Wheel ..................................... 87-101 (118-137)\
15x7" Wheel ....................................... 72-86 (98-117)\
Rear Axle Bearing Retainer Nut ................... 145-173 (196-235)\
INCH Lbs. (N.m)
Master Cylinder Mounting Nut .............................. 115 (13)\
Bleeder Screw ............................................... 71 (8)\
Wheel Cylinder Nut ......................................... 89 (10)\
\
\
\
\
\
\
\

TORQUE SPECIFICATIONS (3000GT)\
\
\
\
\
\
\

Application Ft. Lbs. (N.m)\
Brake Line Flare Nuts ...................................... 11 (15)\
Caliper Guide & Lock Pin Bolt (FWD)
Front .................................................... 54 (73)\
Rear ..................................................... 20 (27)\
Caliper Mounting Bolts
Front .................................................... 66 (90)\
Rear ............................................... 36-43 (49-59)\
Front Axle Shaft Nut ..................................... 166 (230)\
Rear Wheel Bearing Nut
AWD ............................................ 192-221 (260-300)\
FWD .................................................... 170 (230)\
INCH Lbs. (N.m)
Master Cylinder Mounting Nut ............................... 84 (10)\
\
\
\
\
\
\
\

BRAKE SYSTEM BRAKE SPECIFICATIONS
BRAKE SPECIFICATIONS (DIAMANTE)\
\
\
\
\
\
\

Application In. (mm)\
Booster Pushrod Clearance ...................... .016-.024 (.40-.60)\
Disc Runout ............................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear ................................................... .33 (8.4)\
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum)
Front ................................................. 1.08 (2.0)\
Rear .................................................. 1.04 (1.0)\
\
\
\
\
\
\
\

BRAKE SPECIFICATIONS (ECLIPSE)\
\
\
\
\
\
\

Application In. (mm)\
Booster Pushrod Clearance ...................... .023-.033 (.65-.85)\
Disc Runout ............................................. .003 (.08)\
Disc Diameter
AWD .................................................... 9.0 (228)\
Except AWD ............................................. 8.0 (204)\

Page 244 of 1501

$MITSUBISHI MONTERO 1998 Service Manual Disc Thickness (Minimum) Front ................................................. .88 (22.4)\ Rear ................................................... .33 (8.4)\ Drum Inside Diameter (Maximum$

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)\
\
\
\
\
\
\
\

BRAKE SPECIFICATIONS (GALANT)\
\
\
\
\
\
\

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)\
\
\
\
\
\
\
\

BRAKE SPECIFICATIONS (MIRAGE)\
\
\
\
\
\
\

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)\
\
\
\
\
\
\
\

BRAKE SPECIFICATIONS (MONTERO)\
\
\
\
\
\
\

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\
)

Page 245 of 1501

$MITSUBISHI MONTERO 1998 Service Manual (1) - Information not available from manufacturer.��\ ��\ ��\ ��\ ��\ ��\ ��\ ��$

(1) - Information not available from manufacturer.\
\
\
\
\
\
\

BRAKE SPECIFICATIONS (MONTERO SPORT)\
\
\
\
\
\
\

Application In. (mm)\
Disc Runout
Front ................................................. .002 (.06)\
Rear .................................................. .003 (.08)\
Disc Thickness (Minimum)
Front ................................................. .88 (22.4)\
Rear .................................................. .65 (16.4)\
Drum Diameter (Maximum) .............................. 10.71 (272.0\
)
Hub End Play (Maximum) .................................. .002 (.05\
)
Master Cylinder Inside Diameter ........................ .937 (23.8)\
Pad Lining Thickness (Minimum) .......................... 1.08 (2.0\
)
Shoe Lining Thickness (Minimum) ......................... .039 (1.0\
)
Wheel Cylinder Inside Diameter .......................... .90 (22.8)\
\
\
\
\
\
\
\

BRAKE SPECIFICATIONS (3000GT)\
\
\
\
\
\
\

Application In. (mm)\
Booster Pushrod Clearance ...................... .026-.030 (.65-.75)\
Disc Runout
Front
AWD ................................................. .004 (.10)\
FWD ................................................. .003 (.07)\
Rear ................................................ .003 (.08)\
Disc Thickness (Minimum)
Front
AWD ................................................ 1.12 (28.4)\
FWD ................................................. .88 (22.4)\
Rear
AWD ............................................... .72 (18.4)\
FWD ............................................... .65 (16.4)\
Hub End Play ............................................ .002 (.05)\
Master Cylinder Inside Diameter ......................... 1.0 (25.4)\
Pad Lining Thickness (Minimum) .......................... 1.08 (2.0\
)
Parking Brake Drum Diameter (Maximum) ................... 6.65 (169\
)
\
\
\
\
\
\
\

Page 260 of 1501

MITSUBISHI MONTERO 1998 Service Manual specified, bleed system and inspect hydraulic and clutch components.
See CLUTCH PEDAL SPECIFICATIONS table.
CLUTCH PEDAL INTERLOCK SWITCH
1) Place transmission in Neutral and apply

specified, bleed system and inspect hydraulic and clutch components.
See CLUTCH PEDAL SPECIFICATIONS table.
CLUTCH PEDAL INTERLOCK SWITCH
1) Place transmission in Neutral and apply parking brake.
Turn ignition switch to START position with clutch pedal not
depressed. Engine should not crank. If engine cranks, adjust or
replace interlock switch.
2) Disconnect interlock switch connector. Interlock switch
connector is located at clutch pedal. Depress and release interlock
switch. Using ohmmeter, check continuity between interlock switch
terminals. If continuity exists with interlock switch depressed and
does not exist with switch released, switch is okay. Adjust or replace
as necessary.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (2WD Models)
1) Disconnect negative battery cable. Remove shift knob, dust
cover retaining plate, gaskets, stopper plate and control lever
assembly. Raise and support vehicle.
2) Remove front exhaust pipe. Drain transmission fluid. Index
mark drive shaft flange and remove drive shaft.
3) Disconnect back-up light switch connector, speedometer
cable connection and exhaust pipe mounting bracket. Remove lower
bellhousing cover. Disconnect clutch cable from clutch lever.
4) Support transmission with jack. Remove rear engine mount
nuts and bolts from transmission. Remove crossmember with rear engine
mount. Remove remaining bellhousing bolts, move transmission toward
rear and lower from vehicle.
5) If reusing pressure plate, index mark pressure plate to
flywheel for installation reference. Install a clutch alignment tool
to prevent pressure plate and clutch disc from dropping. Loosen
pressure plate bolts gradually in a crisscross pattern to avoid
warping pressure plate flange during removal. Remove pressure plate
and clutch disc. See Fig. 3.
Inspection
1) Check release bearing and release fork for damage or wear.
DO NOT clean release bearing assembly in solvent.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure distance
from clutch disc surface to head of rivet. Replace clutch disc if
distance is less than .012" (.30 mm). Replace worn or defective
components as necessary. See Fig. 4.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. If reusing pressure plate, ensure index marks are
aligned. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS . See Fig. 3.
2) Clean release bearing sliding surface. DO NOT clean

Page 265 of 1501

MITSUBISHI MONTERO 1998 Service Manual Removal & Installation
1) Drain master cylinder. Remove cotter pin, washer and
clevis pin. Disconnect push rod from clutch pedal. Remove and plug
hydraulic line at clutch master cyli

Removal & Installation
1) Drain master cylinder. Remove cotter pin, washer and
clevis pin. Disconnect push rod from clutch pedal. Remove and plug
hydraulic line at clutch master cylinder.
2) Remove retaining nuts, clutch master cylinder and gasket.
To install, reverse removal procedure. Apply grease to clevis pin
before installing. Fill reservoir and bleed clutch system. See
BLEEDING CLUTCH HYDRAULIC SYSTEM .
CLUTCH RELEASE CYLINDER
Removal & Installation
Remove and plug hydraulic line at release cylinder. Remove
cylinder-to-transmission bolts. Remove clutch release cylinder. To
install, reverse removal procedure. Apply grease to push rod-to-
release fork contact area. Bleed clutch system. See
BLEEDING CLUTCH HYDRAULIC SYSTEM .
BLEEDING CLUTCH HYDRAULIC SYSTEM
Attach hose to bleeder fitting located on clutch release
cylinder, next to hydraulic line. Submerge other end of hose in
container half full of clean brake fluid. Fill reservoir with brake
fluid. Open bleeder fitting. Have assistant press clutch pedal to full
release position. Close bleeder fitting. Release clutch pedal. Repeat
until air bubbles no longer emerge from hose. Refill reservoir.
OVERHAUL
CLUTCH MASTER CYLINDER
NOTE: DO NOT disassemble piston assembly.
Disassembly
Remove piston stop ring, damper and push rod assembly. See
Fig. 6 . Remove piston assembly. Note position of reservoir band for
reassembly reference. Remove reservoir.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. On
Montero, adjust clutch master cylinder push rod to 5.90" (150 mm). On
Montero Sport, push rod adjustment is correct after adjusting clutch
pedal free play and pedal height. See CLUTCH PEDAL FREE PLAY and
CLUTCH PEDAL HEIGHT under ADJUSTMENTS. To reassemble, reverse
disassembly procedure. Ensure piston moves freely in bore.
Fig. 6: Exploded View Of Clutch Master Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.

Load next 8 pages

Page: < prev 1-10 ... 25-32 33-40 41-48 49-56 57-64 65-72 73-80 81-88 89-96 ... 160 next >

drain bolt wheel alignment oil additives display reset infotainment system center console