1998 MITSUBISHI MONTERO starter

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.

Clutch Pedal Mounting Nut .................................. 21 (29)\
Flywheel Bolt
Montero .................................................. 54 (74)\
Montero Sport ........................................... 98 (132)\
Fulcrum Ball ............................................... 26 (35)\
Hydraulic Line Flare Nut ................................... 11 (15)\
Push Rod Jam Nut ........................................... 10 (13)\
Release Cylinder Mounting Bolt ............................. 27 (36)\
Starter Mounting Bolt ...................................... 23 (31)\
Transfer Case Roll Stopper Bolt ............................ 33 (44)\
Transmission Crossmember Mounting Bolt ..................... 47 (64)\
Transmission Support Bolt
Front (Crossmember) ...................................... 29 (39\
)
Rear ..................................................... 26 (35)\









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CRUISE CONTROL INDICATOR TEST under COMPONENT TESTS. If cruise control
indicator is defective, replace indicator. If indicator checks okay,
go to next step.
2) If cruise control indicator illuminates when cruise
control connector C-50 terminal No. 23 is grounded at harness side,
replace cruise control ECU. If indicator does not illuminate, check
combination meter connector C-12 and cruise control ECU connector C-
50. Repair as necessary. If connectors are okay and malfunction
remains, check harness between combination meter and cruise control
ECU. Repair as necessary.
Test No. 13
1) Perform stoplight switch test. See
BRAKELIGHT/STOPLIGHT SWITCH TEST under COMPONENT TESTS. If switch is
okay, go to next step. If switch is defective, replace brakelight
switch.
2) Check cruise control ECU connector C-50, stoplight switch
connector C-55 and joint connector C-131. Repair as necessary. See
Figs. 13 , 14, 16 and 29. If connectors are okay and malfunction
remains, check harness between joint connector C-131 and cruise
control ECU.
Test No. 14 (A/T)
1) Perform park/neutral switch test. See
PARK/NEUTRAL SWITCH TEST under COMPONENT TESTS. If switch is okay, go
to next step. If switch is defective, replace switch.
2) Check starter relay. Replace if defective. If relay is
okay, check cruise control ECU connector C-50 and joint connector C-
130. Repair as necessary. See Figs. 13, 16 and 28. If connectors are
okay and malfunction remains, check harness between cruise control ECU
and power supply.
COMPONENT TESTS
ACTUATOR TEST
Remove actuator. Apply vacuum to actuator. Actuator linkage
holder should move more than 1.38" (35 mm). Actuator diaphragm should
hold vacuum. Replace actuator if actuator does not test as specified.
BRAKELIGHT/STOPLIGHT SWITCH TEST
Disconnect stoplight switch connector C-55. When brake pedal
is pressed, continuity should be present between terminals No. 2 and
3. See Fig. 14. When brake pedal is released, continuity should be
present between terminals No. 1 and 4. Replace switch if it does not
test as specified.
CLOCKSPRING TEST
WARNING: Deactivate air bag system before performing any service
operation. See AIR BAG RESTRAINT SYSTEMS article. Do not
apply electrical power to any component on steering column
without first deactivating air bag system. Air bag may
deploy.
If clockspring fails any check, replace with a NEW
clockspring.
1) Check connectors and protective tube for damage and
deformities.
2) Visually check case for damage or deformities.

Headlight Relay In engine compartment
relay box.
Headlight Washer Relay On bracket, behind left side
of dash.
Horn Relay Left front of engine
compartment.
Ignition Key Hole Illumination Light
Timer Behind center console.
Intermittent Wiper Relay (Rear Wiper) In passenger compartment
relay box.
Intermittent Wiper Relay (Windshield
Wiper) Built-in to steering column
switch.
Power Window Relay In passenger compartment
relay box.
Starter Relay Behind center console.

IGNITION SWITCHES
INDICATOR LIGHTS
KEYLESS ENTRY KEYPADS AND TRANSMITTERS
KEYLESS ENTRY TRANSMITTERS
LEDS
LENSES
MICROPHONES
MIRRORS (ELECTROCHROMATIC AND HEATED)
MOTORS
NEUTRAL SAFETY SWITCHES
ODOMETERS
ODOMETERS, SPEEDOMETERS AND TACHOMETERS (CABLE-DRIVEN)
PULLEYS
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS
RELAY BOXES
RELAYS
SEALED BEAMS
SEAT HEATERS
SECURITY ALARM SENSORS
SIRENS
SOLENOIDS
SPEAKERS AND MICROPHONES
SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES
SPEEDOMETER CABLES
SPEEDOMETERS
STARTERS
SUB-WOOFER VOLUME CONTROLS
SWITCHES
TACHOMETER CABLES
TACHOMETERS
TAPE PLAYERS AND CD PLAYERS
TENSIONERS
TIMERS
TIRE PRESSURE SENSORS
TRANSCEIVERS
TRANSDUCERS
VACUUM ACCUMULATORS (RESERVOIRS)
VACUUM RESERVOIRS
VOLTAGE REGULATORS
WASHER FLUID LEVEL SENDERS
WASHER PUMPS
WIPER ARMS AND BLADES
WIPER BLADES
WIPER HOSES AND NOZZLES
WIPER LINKAGES
WIPER NOZZLES
WIPER PUMP RESERVOIRS
WIRING HARNESSES AND CONNECTORS
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,

See HORNS AND SIRENS .
SOLENOIDS
See ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC) .
NOTE: For starter solenoids that are integral to the starter
assembly, see STARTERS.
NOTE: For starter relays, see RELAYS.
SPEAKERS AND MICROPHONES
SPEAKER AND MICROPHONE INSPECTION








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Condition Code Procedure
Application incorrect ... 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.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. B ........... ( 2) Require repair or
replacement. Further
inspection required.
Membrane torn ........... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Polarity reversed ....... A ................. Require repair.
Sound quality poor ...... A ........... ( 3) Require repair or
replacement. Further
inspection required.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
( 3) - Make sure poor sound quality is not caused by
ignition/charging system or other forms of electrical

See GAUGES.
STARTERS
NOTE: To prevent misdiagnosis, care should be taken to
eliminate the possibilities of mechanical problems or
high resistance in power and/or ground circuits.
STARTER INSPECTION









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Condition Code Procedure
Amperage draw does not
meet OEM specifications . B .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ........... ( 1) Require repair or
replacement of hardware.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ........ No service suggested or
required.
Bracket broken, affecting
performance ............ A ............ Require replacement.
Bracket broken, not
affecting performance .. .. ........ No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance) ........... .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Drive gear damaged,
affecting performance .. A ........... ( 2) Require repair or
replacement.
Drive gear damaged, not
affecting performance .. 2 ........... ( 2) Suggest repair or
replacement.
Fails to disengage ...... A .. Require repair or replacement.
Housing broken, affecting
performance ............ 2 .. Require repair or replacement.
Housing broken, not

affecting performance .. .. ........ No service suggested or
required.
Housing cracked, affecting
performance ............ A ... Require repair or replacement.
Housing cracked, not
affecting performance .. 2 .. Suggest repair or replacement.
Inoperative ............. A ........... (3) Require repair or
replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Shimmed incorrectly ..... B ................. Require repair.
Starter shaft bushing
missing ................ C ........ ( 4) Require replacement.
Starter shaft bushing
worn, affecting
performance ............ A ............ Require replacement.
Starter shaft bushing
worn, not affecting
performance ............ 1 ............ Suggest replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 5) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Inspect block or bell housing mounting surface.
( 2) - Further inspection required to determine cause. Require
inspection of ring gear.
( 3) - Inoperative includes intermittent operation.
( 4) - Bushing may be in bell housing.
( 5) - Determine cause and correct prior to repair or
replacement of part.









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SUB-WOOFER VOLUME CONTROLS
See
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS .
SWITCHES
SWITCH INSPECTION








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Condition Code Procedure
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.
Binding, affecting