1998 MITSUBISHI MONTERO jack

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

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert 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 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

AXLE RATIO SPECIFICATIONS








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Application Ratio
Montero ..................................................... 4.27:1
Montero Sport .................................................. (1)
( 1) - On vehicles equipped with wide fender, ratio is 4.64:1. On
vehicles with narrow fender, ratio is 4.27:1.









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LUBRICATION
CAPACITY
DIFFERENTIAL FLUID CAPACITY








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Application Specification
Montero & Montero Sport ............................ 2.4 Pts. (1.1L)\









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FLUID TYPE
All models use fluid type SAE 80W-90/API GL-5.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
AXLE SHAFTS R & I
Removal
1) Raise and support vehicle. Remove wheels and undercover.
Ensure hub is in free-wheeling position. Place transfer case in 2H
position. Remove drive hub cover, snap ring and shim from axle shaft.
See Fig. 3 . Remove brake calipers and support aside.
2) Disconnect tie rod assembly. Support lower control arm
with jack. Separate ball joints from knuckle. Remove knuckle and front
hub assembly. Using flat-blade pry bar, carefully remove left axle
shaft from differential carrier. DO NOT damage oil seal. On right axle
shaft, remove axle shaft-to-inner shaft flange retaining bolts. Remove
right axle shaft.
CAUTION: Replace circlips on BJ/DOJ splined shaft end.
Installation
1) Install right axle shaft on inner shaft flange. Install
new circlip on DOJ side of left axle shaft. Carefully install left
axle shaft into differential. DO NOT damage oil seal.
2) Reinstall knuckle with front hub assembly. To complete
installation, reverse removal procedure. Install shim and snap ring.
Check axle end play. See Fig. 4. End play should be .016-.028" (.4-.7
mm). If end play is not within specification, install correct shim.

into left side axle housing. Install left axle shaft assembly into
axle housing, and tighten nuts to specification. See
TORQUE SPECIFICATIONS.
2) Install right axle shaft assembly into axle housing
without shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case of right axle and rear axle housing end with
feeler gauge.
3) Select shims equal to sum of measured clearance plus .002-
.008" (.05-.20 mm). Remove right axle shaft, and install selected
shim(s) and "O" ring into right axle housing end. Install right axle
shaft assembly into rear axle housing. Tighten nuts in diagonal
sequence to specification. See TORQUE SPECIFICATIONS.
4) Using dial indicator, check end play of axle shaft. End
play should be .002-.008" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake, and bleed brake system.
CARRIER ASSEMBLY
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFT R & I . Support differential carrier with jack.
Remove differential carrier retaining nuts. Remove differential
carrier.
Inspection
Check for leaks at vent plug, differential carrier companion
flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts and drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
OVERHAUL
AXLE SHAFT OVERHAUL
Removal
1) Secure axle shaft assembly in a vise, and remove one
retainer bolt from backing plate. Push bearing case completely to side
of dust cover. Place adhesive tape around edge of bearing case at
retainer bolt hole to prevent damage.
CAUTION: DO NOT damage bearing case or axle shaft when grinding or
chiseling retainer ring.
2) Secure axle shaft, and grind retainer ring until retainer
ring wall thickness is .04-.06" (1.0-1.5 mm) on axle shaft side and .
08" (2.0 mm) on bearing side. See Fig. 4.

CYLINDER BLOCK
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
BLOCK CLEANING
Only cast cylinder blocks should be hot tank cleaned.
Aluminum cylinder blocks should be cleaned using cold tank method.
Cylinder block is cleaned in order to remove carbon deposits, gasket
residue and water jacket scale. Remove oil galley plugs, freeze plugs
and cam bearings prior to block cleaning.
BLOCK INSPECTION
Visually inspect the block. Check suspected areas for cracks
using the Dye Penetrant inspection method. Block may be checked for
cracks using the Magnaflux method.
Cracks are most commonly found at the bottom of the
cylinders, the main bearing saddles, near expansion plugs and between
the cylinders and water jackets. Inspect lifter bores for damage.
Inspect all head bolt holes for damaged threads. Threads should be
cleaned using tap to ensure proper head bolt torque. Consult machine
shop concerning possible welding and machining (if required).
CYLINDER BORE INSPECTION
Inspect the bore for scuffing or roughness. Cylinder bore
is dimensionally checked for out-of-round and taper using dial bore
gauge. For determining out-of-round, measure cylinder parallel and
perpendicular to the block centerline. Difference in the 2 readings
is the bore out-of-round. Cylinder bore must be checked at top, middle
and bottom of piston travel area.
Bore taper is obtained by measuring bore at the top and
bottom. If wear has exceeded allowable limits, block must be honed
or bored to next available oversize piston dimension.
CYLINDER HONING
Cylinder must be properly honed to allow new piston rings to
properly seat. Cross-hatching at correct angle and depth is critical
to lubrication of cylinder walls and pistons.
A flexible drive hone and power drill are commonly used.
Drive hone must be lubricated during operation. Mix equal parts of
kerosene and SAE 20w engine oil for lubrication.
Apply lubrication to cylinder wall. Operate cylinder hone
from top to bottom of cylinder using even strokes to produce 45 degree
cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone
to extend below cylinder during operation.
Recheck bore dimension after final honing. Wash cylinder
wall with hot soapy water to remove abrasive particles. Blow dry with
compressed air. Coat cleaned cylinder walls with lubricating oil.
DECK WARPAGE
Check deck for damage or warped head sealing surface. Place
a straightedge across gasket surface of the deck. Using feeler gauge,
measure clearance at center of straightedge. Measure across width and

DISTRIBUTOR
NOTE: Eclipse, Mirage 1.8L, Montero, Montero Sport 3.0L and 3000GT
DOHC use Distributorless Ignition System (DIS). All other
models use distributor type ignition systems with
non-serviceable distributors on which only the rotor and
distributor cap can be changed.
FUEL SYSTEM
* PLEASE READ THIS FIRST *
WARNING: Always relieve fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
FUEL SYSTEM PRESSURE RELEASE
Relieving Fuel Pressure
1) On Diamante, disconnect fuel pump harness connector at
fuel tank from underneath vehicle. On Montero and Montero Sport,
remove cargo compartment carpet, remove access plate and disconnect
fuel pump harness connector. On all other models, remove rear seat
cushion and remove access plate (if required) to disconnect fuel pump
harness connector.
2) On all models, start engine. Let engine run until it
stops. Turn ignition off. Disconnect negative battery cable. Connect
fuel pump harness connector. Reinstall rear seat (if necessary.)
FUEL PUMP
Removal & Installation (Diamante, Eclipse, Galant & Montero)
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove access panel
under seat, in trunk or in rear cargo area. Disconnect electrical
connectors and fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Remove fuel pump
assembly. To install, reverse removal procedure. Tighten nuts to
specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Mirage, Montero Sport & 3000GT)
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Raise vehicle on
hoist. Drain fuel into suitable container. Disconnect electrical
connectors and breather/fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Support fuel tank
with transmission jack. Remove nuts securing fuel tank. Remove fuel
tank from vehicle. Remove fuel pump assembly. To install, reverse
removal procedure. Tighten nuts to specification. See
TORQUE SPECIFICATIONS .
FUEL RAILS & INJECTORS
WARNING: Use a rag to cover fuel hose connection before disconnecting
high pressure fuel hose at fuel rail. Some residual fuel
pressure may still be in system.
CAUTION: DO NOT drop injectors while removing or installing fuel rail.
Removal (Diamante, Montero Sport 2.4L & 3000GT)

replace left bracket bushing.
NOTE: Tighten lower control arm shaft and pivot bolt to
specification with vehicle at normal operating height.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Tighten lower control arm
shaft and pivot bolt to specification with vehicle at normal operating
height.
STABILIZER BAR
Removal
Remove skid plate (if equipped). Disconnect stabilizer bar
link bolt. Remove stabilizer bar clamp bolts. Remove stabilizer bar
and bushings. On Montero Sport remove the stabilizer link brackets and
bushings.
Installation
1) To install, reverse removal procedure. Note that slit in
stabilizer bushing faces vehicle. Marks on bar should be approximately
0.39" (10 mm) from edge of bracket. On Montero Sport adjust the
stabilizer link assembly mounting nut so there is 0.2-0.3" (6-8 mm) of\
threads exposed from the top of the nut to the top of the threads.
TORSION BAR
NOTE: Mark torsion bar and anchor arm location for reassembly
reference before removing.
Removal
1) Raise and support vehicle. Support lower control arm using
jack stand. Loosen anchor arm adjusting bolt lock nut. Remove heat
protector from frame (right side only). Loosen anchor arm bolt to
release torsion bar tension.
2) Mark front of torsion bar and torque arm for reassembly
reference. Remove anchor arm. See Fig. 1. Remove dust covers from
torsion bar. Remove heat cover (right side only) located between dust
cover and torsion bar. Remove torsion bar.
Inspection
Inspect all splined areas for damage. Inspect dust covers for
cracks and damage. Check for bent anchor arm bolts. Replace components
as necessary.
Installation
1) Apply grease to splined areas of torsion bar, anchor arm,
torque arm splines, anchor arm bolt threads and inside of dust cover.
Check for left and right identification marks on torsion bar ends.
Ensure torsion bars are installed in correct locations.
2) Install torsion bar in torque arm, with identification
mark toward front of vehicle and the slit in the anchor collar facing
downward. Align mark on torque arm with mating mark on torsion bar.
When installing a new torsion bar, align White paint spline with index
mark on front anchor arm.
3) Tighten anchor arm bolt adjusting nut to obtain correct
final bolt protrusion. See FINAL ANCHOR ARM BOLT PROTRUSION table.
Final bolt protrusion depends upon curb weight of vehicle. With
vehicle unladen, measure distance from bump stopper bracket to bump
stopper. Distance should be 0.83-0.91" (21-23 mm) on Montero, 0.7" (1\
8
mm) on Montero Sport. If not, adjust anchor bolt nut.

FINAL ANCHOR ARM BOLT PROTRUSION








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Application/ Right Bolt Left Bolt
Model In. (mm) In. (mm\
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Montero ................... 3.15 (80.0) .............. 3.15 (80.0\
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4) To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. Check
riding height and front wheel alignment. See WHEEL ALIGNMENT
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section.
UPPER BALL JOINT
Removal
1) Raise and support vehicle. Remove wheel assembly. Mark
torsion bar adjusting nut for reassembly reference. Release torsion
bar tension. Loosen, but DO NOT remove, upper ball joint-to-steering
knuckle nut.
2) Using Steering Linkage Puller (MB991406), separate ball
joint from steering knuckle. Remove ball joint nut from steering
knuckle. Remove ball joint-to-upper control arm bolts. Remove ball
joint.
Installation
Lubricate ball joint. To complete installation, reverse
removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS .
SHOCK ABSORBER & UPPER CONTROL ARM
Removal
1) Disconnect actuator on vehicles with Variable Shock
Absorbers. On all models, raise and support vehicle. Support lower
control arm using jackstand. Remove front wheels. Remove lower shock
absorber bolt. Remove nut from top of shock absorber and remove shock
assembly from vehicle.
2) Remove the bump stop from the bump stop bracket. Mark
anchor arm bolt for reassembly reference. Loosen anchor arm bolt to
release torsion bar tension. Disconnect and plug brake hose at frame
mount bracket.
3) Remove cotter pin from upper ball joint stud. Loosen, but
DO NOT remove, ball joint stud nut. Using Steering Linkage Puller
(MB991406), loosen ball joint from steering knuckle. Remove brake hose\
clip and rebound stopper. Remove rebound stopper and brake hose
support from control arm.
4) Remove ABS sensor bracket (if equipped) and rebound
stoppers. Remove upper control arm mounting bolts and shim(s). Note
direction of bolt installation and locations of camber adjustment
shims. Remove control arm. Remove upper ball joint from control arm.
Inspection
Inspect control arm for cracks and deformation. Check ball
joints. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION.
Inspect ball joint dust cover for damage, and replace cover as
necessary.
Installation
1) To install, reverse removal procedure. Install control arm
bolts from outside of frame, with nuts against control arm. Install
the upper control with the marking "OUT" on shaft facing outside of
vehicle.