1998 MITSUBISHI MONTERO transmission oil

this information to control solenoids on transmission valve body. TCM
controls transmission shifting and torque converter lock-up.
TCM contains a self-diagnostic system, which will store
Diagnostic Trouble Codes (DTC) if failure or problem exists in
electronic control system. DTC can be retrieved to determine problem
area. See SELF-DIAGNOSTIC SYSTEM. TCM is located under left side of
instrument panel, left of steering column. See Fig. 1.
TCM INPUT DEVICES
Brakelight Switch Signal
Brakelight switch delivers input signal to TCM, indicating
vehicle braking. Brakelight switch is located on brake pedal support.
Cruise Control Electronic Control Unit (ECU)
Cruise control ECU delivers an input signal to control
overdrive operation in accordance with vehicle speed when cruise
control is operating. When in overdrive with cruise control on, if
vehicle speed drops 2 MPH less than the set speed, overdrive is
released to prevent reduction in vehicle speed. Once vehicle speed is
more than the set speed, overdrive function is resumed. If coolant
temperature is low, transmission will not shift into overdrive. Cruise
control ECU is located below center A/C vent, behind temperature
control panel on Montero. On Montero Sport, cruise control ECU is
located behind driver's kick panel.
Engine Coolant Temperature Sensor (ECT) Signal
Engine coolant temperature sensor delivers input signal to
TCM, indicating engine coolant temperature. Coolant temperature sensor
is located on engine.
Input & Output Shaft Speed Sensors
Sensors are magnetic pick-ups that monitor input and output
shaft speeds. AC waveforms are input to TCM by sensors. Sensors are
located on front and rear side of transmission case.
OD Switch Signal
The OD switch provides an input signal to TCM to indicate
when overdrive is selected by operator. When OD switch is depressed to
ON position, transmission will shift into 4th gear when shift lever is
in "D" position, and OD OFF light on instrument panel will go off.
When OD switch is released to OFF position, transmission will shift
into 3rd gear, and OD OFF light on instrument panel will come on. The
OD switch is mounted on shift lever.
Oil Temperature Sensor Signal
Oil temperature sensor provides TCM with ATF temperature
values. TCM uses this information to control shift points for maximum
performance. If transmission oil temperature exceeds standard values,
instrument panel ATF - TEMP light will come on. Sensor is mounted to
cooler line at transmission.
Park/Neutral Position (PNP) Switch Signal
PNP switch delivers an input signal to TCM indicating shift
lever position. Switch is located on side of transmission.
Throttle Position (TP) Sensor Signal
TP sensor delivers closed throttle and variable throttle
position input signals to TCM. TP sensor is located on side of
throttle body.
4WD Low Range Detection Switch
4WD low range detection switch provides information to TCM

If DTC 51 is set also, go to DTC 51: 1ST GEAR RATIO SIGNAL
INCORRECT test. If DTC 51 is not set, check overdrive brake for a
mechanical failure. See OVERDRIVE BRAKE in MITSUBISHI R4AW3 & V4AW3
OVERHAUL article.
SYMPTOM TROUBLE SHOOTING
NOTE: Check system using appropriate scan tool. See WIRING DIAGRAMS
for electrical schematics and COMPONENT TESTING.
COMMUNICATION WITH SCAN TOOL NOT POSSIBLE
If scan tool cannot communicate with TCM, check proper
connection with DLC. Check TCM power circuits, TCM ground circuits and
malfunctioning TCM.
SHIFT POINTS INCORRECT
If shift points are incorrect, check for DTCs. If no DTC is
present, check oil temperature sensor, pattern select switch, 4WD low
range detection switch and TCM for proper operation.
UPSHIFTS OCCUR SPONTANEOUSLY
If upshifting occurs spontaneously, check park/neutral
position switch, overdrive switch and TCM for proper operation.
TCC LOCK-UP MALFUNCTIONING
If TCC lock-up system is not operating properly, check torque
converter, valve body, lock-up switch and oil temperature switch.
COMPONENT TESTING
A/T FLUID TEMPERATURE SWITCH
1) Remove fluid temperature switch, located to rear of
neutral safety switch. Immerse switch in container of ATF up to top
threaded portion of switch. Using a DVOM, check continuity between
switch terminals. Continuity should not exist when fluid temperature
is 257
F (125C) or less.
2) When fluid is heated to 289-304F (143-151C), continuity
should exist. Replace switch if necessary. Apply thread sealant to
fluid temperature switch threads and install in transmission.
BRAKELIGHT SWITCH
1) Disconnect electrical connector from brakelight switch,
located near brake pedal. Using ohmmeter, ensure continuity exists
between terminal No. 2 (White/Red wire) and terminal No. 3 (Green
wire) with brake pedal released. Replace brakelight switch if
continuity does not exist. Continuity should not exist between
terminals No. 2 and No. 3 with brake pedal depressed.
2) If continuity does not exist, ensure brake pedal is
properly adjusted so brakelight switch has proper travel for switch
operation. If proper brakelight switch travel exists, replace
brakelight switch.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR

until brakelight plunger contacts brake pedal.
2) Loosen brakelight switch 1/2 to one turn. Install and
tighten lock nut on brakelight switch. Install electrical connector.
Ensure brakelights and cruise control operate properly.
INPUT SPEED SENSOR
Removal & Installation
Disconnect electrical connector. Remove bolt securing sensor
to transmission. Remove input speed sensor from transmission. See
Fig. 14 . To install, reverse removal procedure.
Fig. 14: Locating Input Speed Sensor
Courtesy of Mitsubishi Motor Sales of America.
OIL TEMPERATURE SENSOR
Removal & Installation
Sensor is located on transmission connected to cooler line,
near PNP switch. Disconnect electrical connector. Remove oil
temperature sensor from transmission. To install, reverse removal
procedure using NEW gasket.
OUTPUT SPEED SENSOR
Removal & Installation

Montero .............................. 10.0 Qts. (9.5L)
Montero Sport
2.4L
With Rear Heater .................. 9.5 Qts. (9.0L)
Without Rear Heater ............... 8.5 Qts. (8.0L)
3.0L
With Rear Heater ................ 10.6 Qts. (10.0L)
Without Rear Heater ............... 9.5 Qts. (9.0L)
3000GT ................................ 8.5 Qts. (8.0L)
Crankcase (Includes Filter)
Diamante ............................... 4.5 Qts. (4.3L)
Eclipse
Non-Turbo ............................ 4.5 Qts. (4.3L)
2.0L Turbo ........................... 4.6 Qts. (4.4L)
Galant ................................. 4.5 Qts. (4.3L)
Mirage
1.5L ................................. 3.5 Qts. (3.3L)
1.8L ................................. 4.0 Qts. (3.8L)
Montero ............................ (1) 5.0 Qts. (4.8L)
Montero Sport
2.4L ................................. 4.5 Qts. (4.3L)
3.0L ................................. 5.2 Qts. (4.9L)
3000GT
Non-Turbo ............................ 4.5 Qts. (4.3L)
Turbo ................................ 5.0 Qts. (4.6L)
Differential (SAE 80W-90/API GL-5)
Eclipse ................................... .9 Qt. (.8L)
Montero
Front ................................ 1.3 Qts. (1.2L)
Rear ................................. 3.3 Qts. (3.2L)
Montero Sport
Front ................................ 1.2 Qts. (1.1L)
Rear
2.4L ............................... 1.6 Qts. (1.5L)
3.0L ............................... 2.7 Qts. (2.6L)
3000GT ................................. 1.2 Qts. (1.1L)
Manual Transaxle (SAE 75W-85/API GL-4)
Eclipse
Non-Turbo ( 2) ........................ 2.1 Qts. (2.0L)
Turbo
AWD ................................ 2.4 Qts. (2.3L)
FWD ................................ 2.1 Qts. (2.0L)
Galant ................................. 2.3 Qts. (2.2L)
Mirage
1.5L ................................. 2.2 Qts. (2.1L)
1.8L ................................. 2.3 Qts. (2.2L)
3000GT
AWD .................................. 2.5 Qts. (2.4L)
FWD .................................. 2.4 Qts. (2.3L)
Manual Transmission (SAE 75W-85/API GL-4)
Montero ................................ 3.3 Qts. (3.2L)
Montero Sport .......................... 2.4 Qts. (2.3L)
Power Steering (Dexron-II)
3000GT W/4-Wheel Steering .............. 3.2 Pts. (1.5L)
Montero ................................ 2.2 Pts. (1.1L)
All Others .............................. 1.9 Pts. (.9L)
Transfer Case (SAE 75W-85/API GL-4)
Eclipse (AWD) ........................... 1.1 Pts. (.5L)
Montero ................................ 5.0 Pts. (2.5L)
Montero Sport .......................... 4.6 Pts. (2.3L)
3000GT .................................... .7 Pt. (.3L)
( 1) - Add .5 qt. (.3L) if oil cooler is drained.

Oil ................................................. 7500
Oil Filter .................................... (3) 15,000
Spark Plugs ....................................... 30,000
Spark Plug Wires .................................. 60,000
Timing & Balance Shaft Belts ...................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Inspect fluid every 30,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 3) - Replace oil filter at oil change if annual mileage is
less than 7500 miles.









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REPLACEMENT INTERVALS TABLE (MIRAGE)








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Component Miles
Air Filter ........................................ 30,000
Automatic Transaxle Fluid ............................ ( 1)
Coolant .............................................. ( 2)
Oil ................................................. 7500
Oil Filter .................................... ( 3) 15,000
Spark Plugs ....................................... 30,000
Spark Plug Wires .................................. 60,000
Timing Belt ....................................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Inspect fluid every 30,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 3) - Replace oil filter at oil change if annual mileage is
less than 7500 miles.









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REPLACEMENT INTERVALS TABLE (MONTERO)








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Component Miles
Air Filter ........................................ 30,000
Automatic Transmission Fluid ......................... ( 1)
Coolant ........................................... 30,000
Front & Rear Axle Fluid ( 2) ....................... 30,000
Oil ................................................. 7500
Oil Filter .................................... ( 3) 15,000
Manual Transmission .................................. ( 4)
Spark Plugs ( 5) ................................... 60,000
Spark Plug Wires .................................. 60,000
Timing Belt ....................................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Limited-slip differential.
( 3) - Replace oil filter at oil change if annual mileage is
less than 7500 miles.
( 4) - Inspect fluid every 30,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.

(5) - Use Platinum spark plugs only.








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REPLACEMENT INTERVALS TABLE (MONTERO SPORT)








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Component Miles
Air Filter ........................................ 30,000
Automatic Transmission
Except 4WD ......................................... ( 1)
4WD ............................................. 30,000
Axle Fluid ( 2) .................................... 30,000
Coolant ........................................... 30,000
Oil ................................................. 7500
Oil Filter .................................... ( 3) 15,000
Spark Plugs ( 4) ................................... 60,000
Spark Plug Wires .................................. 60,000
Timing Belt ....................................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Limited-slip differential.
( 3) - Replace oil filter at oil change if annual mileage is
less than 7500 miles.
( 4) - Use Platinum spark plugs only.









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REPLACEMENT INTERVALS TABLE (3000GT)








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Component Miles
Air Filter ........................................ 30,000
Automatic Transaxle Fluid ............................ ( 1)
Coolant ........................................... 30,000
Oil
Non-Turbo ......................................... 7500
Turbo ............................................. 5000
Oil Filter
Non-Turbo ....................................... 15,000
Turbo ........................................... 10,000
Spark Plugs
Except Platinum ................................. 30,000
Platinum ........................................ 60,000
Spark Plug Wires ( 2) .............................. 60,000
Timing Belt ....................................... 60,000
( 1) - Inspect fluid every 15,000 miles. Replace fluid if
evidence of contamination appears, after repairing
reason for contamination.
( 2) - Except vehicles equipped with Federal Emissions.









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BELT ADJUSTMENT TABLE








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( 1) Deflection ( 1) Deflection
Application New Belt - In. (mm) Used Belt - In. (mm\
)
Diamante
Generator & A/C .... .24-.28 (6.0-7.2) ....... .32-.37 (8.2-9.3\
)
P/S ................ .33-.37 (8.4-9.3) ..... .46-.52 (11.7-13.4\
)
Eclipse
2.0L Non-Turbo

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

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.
CLUTCH RELEASE BEARING & RELEASE FORK
Removal (2WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
clips, release bearing and carrier. Use a punch to remove shift arm
spring pin and release lever assembly. Remove shift arm, felt packing
and 2 return springs. See Fig. 5.
2) Ensure release bearing turns freely and smoothly under
light load. Replace bearing if noise, roughness or dryness is present.
DO NOT clean bearing in solvent. Use shop towel or compressed air
only.
Installation
1) Insert lever and shaft into left side of transmission
case. Place shift arm, felt packing and return springs on shaft
assembly. Apply grease to inside of bushing and oil seal lips. Apply
oil to felt packing.
2) Align shift arm pin and control shaft pin holes. Drive
spring pins into position, with slit area upward. Reverse removal
procedure to complete installation. Check pedal height and free play.
Adjust if necessary. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS.
Removal (4WD Models)
1) Remove transmission. See CLUTCH ASSEMBLY. Remove return
spring or clips, and remove release bearing.
2) Slide release fork toward outside of transmission and
disengage from fulcrum ball. DO NOT slide release fork toward inside
of case, or damage to fulcrum ball clip will result. Remove release
fork boot.
Installation
To install, reverse removal procedure. Apply grease to
fulcrum ball contact area of release fork before installing. Fill
groove of release bearing inside diameter with grease before
installing. See Fig. 5.