2000 MITSUBISHI MONTERO Oil

G
EN ER AL IN FO RM ATIO N
I te m s S
pecif ic a tio ns T
ra nsm is sio n model V
5M T1 V
5M 31 E
ngin e model 4
D 5 4
D 5 4
M 4 6
G 7 T
yp e 5
-s p eed, flo or-s h if t G
ear ra tio 1
st 3
.9 18 3
.9 52 4
.2 34 2
nd 2
.2 61 2
.2 38 3
rd 1
.3 95 1
.3 98 4
th 1
.0 00 5
th 0
.8 29 0
.8 19 0
.7 61 0
.8 19 R
eve rs e 3
.9 25 3
.5 53 T
ra nsfe r ty p e 2
-s p eed G
ear ra tio H
ig h 1
.0 00 L
ow 1
.9 25 1
.9 00 S
pecif ie d lu bric a nts Q
uantit y L T
ra nsm is sio n oil H
yp oid gearo il S AE 75W -9 0 or7 5W -8 5W co nfo rm in g to
A PIG L-4 3
.2 T
ra nsfe r oil H
yp oid gearo il S AE 75W -9 0 or7 5W -8 5W co nfo rm in g to
A PIG L-4 2
.5 S
pecif ie d se ala nt R
em ark s O
il fille r plu g 3
M AT D Part N o. 8660 or equiv a le nt S
em i- d ry in g se ala nt O
il d ra in plu g 3
M AT D Part N o. 8660 or equiv a le nt S
em i- d ry in g se ala nt N
um ber N
am e U
se M
D998464 T
e st harn ess
( 4 P, sq uare ) I
n sp ectio n of le ve r posit io n se nso r

O
N-V EH IC LE SER VIC E
T R ANSM IS SIO N OIL CHEC K
1 . Rem ove th e oil fille r plu g.
2 . Oil le ve l sh ould be at th e lo w er portio n of th e fille r plu g
h ole .
3 . Check th at th e tr a nsm is sio n oil is not notic e ably dir ty ,
a nd th at it has a su it a ble vis co sit y .
4 . Tig hte n th e fille r plu g to th e sp ecif ie d to rq ue.
T ig hte n in g to rq ue: 32 ±
2 N×
m
O IL REPLA CEM EN T
1 . Rem ove oil fille r plu g and oil dra in plu g.
2 . Dra in oil.
3 . Apply se ala nt to th e oil dra in plu g th re ads.
4 . Tig hte n th e oil dra in plu g to th e sp ecif ie d to rq ue.
T ig hte n in g to rq ue:
V 5M T1 39 ±
5 N×
m
V 5M 31 32 ±
2 N×
m
T ra n sfe r 32 ±
2 N×
m
S pecif ie d seala n t:
3 M ATD Part No. 8660 or eq uiv ale n t
5 . Fill w it h sp ecif ie d oil till th e le ve lc o m es to th e lo w erp ortio n
o f oil fille r plu g hole .
S pecif ie d tr a n sm is sio n oil:
H yp oid gear oil SA E 75W -9 0 or 75W -8 5W
c o nfo rm in g to API G L-4
Q uan tit y :
T ra n sm is sio n 3.2 L
T ra n sfe r 2.5 L
6 . Apply se ala nt to th e oil fille r plu g th re ads.
7 . Tig hte n th e oil fille r plu g to th e sp ecif ie d to rq ue.
T ig hte n in g to rq ue: 32 ±
2 N×
m
S pecif ie d seala n t:
3 M ATD Part No. 8660 or eq uiv ale n t F
ille r plu g hole O
il d ra in plu g O
il fille rp lu g O
il d ra in plu g T
ra n sfe r
< V 5M T1> O
il fille rp lu g O
il d ra in plu g O
il fille rp lu g O
il fille rp lu g O
il d ra in plu g

23-1
AUTOMATIC
TRANSMISSION
CONTENTS
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
SPECIAL TOOLS 2..........................
TROUBLESHOOTING
3.....................................
>70................................

92 ..........................................
ON-VEHICLE SERVICE 94...................
Basic Adjustment Procedures 94.................
Transfer Oil Check 99...........................
Transfer Oil Change 99.........................
Location of Control Components 101..............
Control Component Checks 102..................
Torque Converter Stall Test 105..................
Fluid Pressure Test 106.........................Hydraulic Circuit 110............................
Line Pressure Adjustment 111...................
Selector Lever Operation Check 111..............
Transfer Shift Lever Operation Check 114........
Transmission Control Cable Adjustment 114......
Transfer-ECU Check 115........................
Position Indicator Lamp Check 115...............
TRANSMISSION CONTROL* 116.............
SHIFT LOCK AND KEY INTERLOCK
MECHANISMS* 120..........................
TRANSMISSION ASSEMBLY 122.............
TRANSMISSION OIL COOLER 127...........
A/T-ECU 129................................
TRANSFER-ECU 130........................
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting
wiring. Other SRS-related components (that mayhave to be removed/installed in connectionwith SRS service or maintenance) are
indicated in the table of contents by an asterisk(*).


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

S
ER VIC E SPEC IF IC ATIO NS
I te m S
ta ndard va lu e A
/T flu id te m pera tu re se n- A
t0°C 1
6.7 -20.5 s
o r re sis ta nce kW 7
.3 -8.9 A
t40°C 3
.4 -4.2 A
t60°C 1
.9 -2.2 A
t80°C 1
.0 -1.2 A
t100 °C 0
.5 7 -0.6 9 D
am per clu tc h co ntr o l(D CC)so le noid va lv e co il re sis ta nce (a t 20°C )W L
ow &re ve rs e (L R )so le noid va lv e co il re sis ta nce (a t 20°C )W S
eco nd (2 N D)so le noid va lv e co il re sis ta nce (a t 20°C )W U
nderd riv e so le noid va lv e (U D so le noid va lv e ) co il re sis ta nce (a t 20°C )W O
ve rd riv e so le noid va lv e (O D so le noid va lv e ) co il re sis ta nce (a t 20°C )W R
esis ta nce of re ductio n (R ED )so le noid va lv e co il a t (2 0°C )W S
ta ll s p eed r/m in 6
G 7 2
,2 00 -2,7 00 4
M 4 2
,4 00 -2,9 00 L
in e pre ssu re adju stm ent va lu e kP a 1
,0 10 -1,0 50 B
ra nd Q
uantit y L T
ra nsm is sio n flu id D
IA QUEEN AT F SP II M ,A T F SP III or equiv a le nt 9
.3 T
ra nsfe r oil H
yp oid gear oil S AE 75W -9 0 or 75W -8 5W co nfo rm in g to API
G L-4 2
.8 N
o. N
am e A
pplic a tio n M
B991502 M
UT-II S ub
a sse m bly D
ia gnosis co de ch eckin g M
B991529 D
ia gnosis co de
c h eckin g harn ess M
B991658 T
e st harn ess V
olt a ge measu re m ent of APS M
D998478 T
e st harn ess
( 3 P, tr ia ngle ) V
olt a ge measu re m ent of cra nk angle se nso r

AUTOMATIC TRANSMISSION -Troubleshooting 23-49
Inspection procedure 2
Starting not possible
Probable cause
If the enginewill not start when the selector lever is at the P or N position, the
cause is probably a malfunction of the inhibitor switch system, the transmission
control cable assembly, theenginesystem, the torque converter or the oil pump.DMalfunction of inhibitor switch system
DMalfunction of transmission control cable assembly
DMalfunction of enginesystem
DMalfunction of torque converter
DMalfunction of oil pump
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
LRefer to the Transmission Workshop Manual.
NG
Inspection Procedure 16: Inhibitor switch system check (Refer
to P.23-58.)NG
Repair or replace
OK
Torque converter check
DCheck for incorrect installation (inserted at an angle, etc.)
or damagedsplines.NGIf repair is possible, repair the damaged part.
If repair is not possible because the splines aredamaged,
replace the torque converter assembly.
OK
Replace the oil pumpassembly.
L
(The oilpump cannot be disassembled.)
Engine system check
DControl system, ignition system, fuel system, vehicle bodyNG
Repair
OK
Transmission control cable assembly checkNG
Repair OK
Check the trouble symptoms.Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 3
Does not move forward
Probable cause
If the vehicle does not move forward when theengine is idling and theselector
lever is moved from N to D, 3, 2 or L, or if it is shifted to 1st or 2nd in Sports
mode, the cause is probably a problem with line pressure, or a malfunction of
the UD clutch or valve body.DAbnormal line pressure
DMalfunction of UD solenoid valve
DMalfunction of UD clutch system
DMalfunction of valve body
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
LRefer to the Transmission Workshop Manual.
MUT-
IIActuator Test
DNo.2 UD solenoid valve
OK:Sound of operation can be heardNGReplace the solenoid valve.
L
OK
Fluid pressure test (Refer to P.23-106.)
DMeasure the fluid pressure at each element in 1st in
Sportsmode
Standard value:Refer to P.23-106.NGDisassemble, clean and re-assemble the valve body.
L
DMake sure that the mounting bolts are not loose and that
the O-ring and valve body are notdamaged or positioned
incorrectly.
DIf the extent of thedamagelooks too bad for repairs to be
carried out, replace the valve body assembly.
OK
UD clutch system check
DRemove the transmission assembly, the valve body cover
and the valve body.
DBlow air through the UD clutch oilhole in the transmission
case, and check that the piston operates to maintain
pressure.
UD clutch check
L
DCheck for a problem such as burnt facing, poor piston
sealing or interference with the retainer.OKCheck the trouble symptoms. NG
Replace the engine-A/T-ECU or A/T-ECU.NG


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

AUTOMATIC TRANSMISSION -Troubleshooting 23-50
Inspection procedure 4
Does not reverse
Probable cause
If the vehicle does not reverse when theengine is idling and theselector lever
is moved from N to R, the cause is probably a problem with reverse clutch
pressure or LR brake pressure, or a malfunction of the reverse clutch, LD clutch
or valve body.DAbnormal reverse clutch pressure
DAbnormal LR brake pressure
DMalfunction of LR solenoid valve
DMalfunction of reverse clutch
DMalfunction of LR brake
DMalfunction of valve body
DReplacement of engine-A/T-ECU <6G7>
DReplacement of A/T-ECU.<4M4>
LRefer to the Transmission Workshop Manual.
NGReplace the solenoid valve.
L
OK
NG
OK
NG
Disassemble, clean and re-assemble the valve body.
L
DMake sure that the mounting bolts are not loose and that
the O-ring and valve body are notdamaged or positioned
incorrectly.
DIf the extent of thedamagelooks too bad for repairs to be
carried out, replace the valve body assembly.
OK
Reverse clutch system and LR brake system check
L
DRemove the transmission assembly, the valve body cover
and the valve body.
DBlow air through the reverse clutch oilhole or LRbrake
air hole in the transmissioncase, and check that the
piston operates to maintain pressure.OK
Check the reverse clutch and LR brake.
L
DCheck for a problem such as burnt facing, poor piston
sealing or interference with the retainer.NGCheck the trouble symptoms.
Replace the engine-A/T-ECU or A/T-ECU.NG
MUT-
IIActuator Test
DNo. 1 LR solenoid valve
OK:Sound of operation can be heard
Fluid pressure test (Refer to P.23-106.)
DMeasure the reverse clutch fluid pressure in R range.
Standard value:Refer to P.23-106.
Fluid pressure test (Refer to P.23-106.)
DMeasure the LR brake fluid pressure in R range.
Standard value:Refer to P.23-106.


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

AUTOMATIC TRANSMISSION -Troubleshooting AUTOMATIC TRANSMISSION -Troubleshooting 23-51
Inspection procedure 5
Does not move (forward or reverse)
Probable cause
If the vehicle does not move forward or reverse when the selector lever is
moved to any position while the engine is idling, thecause is probably a
problem with line pressure or a malfunction of the oil pumps and valve bodies in
the power train.DAbnormal line pressure
DMalfunction of power train components
DMalfunction of oil pump
DMalfunction of valve body
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
LRefer to the Transmission Workshop Manual.
Fluid pressure test (Refer to P.23-106.)
DMeasure the fluid pressure at each element in 1st, 2nd
and reverse.
Standard value:Refer to P.23-106.OKCheck the power train components
L
DDisassemble the transmission and check the condition of
components such as the planetary carrier, output shaft and
differential.
NG
Replace the oil pumpassembly.
L
(The oilpump cannot be disassembled.)
Disassemble, clean and re-assemble the valve body.
L
DMake sure that the mounting bolts are not loose and that
the O-ring and valve body are notdamaged or positioned
incorrectly.
DIf the extent of thedamagelooks too bad for repairs to be
carried out, replace the valve body assembly.NG
NG
Check the trouble symptoms.
Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 6
Engine stalls during shifting
Probable cause
If the enginestalls when the selector lever is moved from N to D or R while the
engine is idling, thecause is probably a malfunction of theenginesystem, DCC
solenoid valve, valve body, or torque converter (damper clutch).DMalfunction of enginesystem
DMalfunction of DCC solenoid valve
DMalfunction of valve body
DMalfunction of torque converter (malfunction of
damper clutch)
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
LRefer to the Transmission Workshop Manual.
Engine system check
DControl system, ignition system, fuel system, vehicle bodyNG
Repair or replace
OK
Replace the DCC solenoid valve.
L
Disassemble, clean and re-assemble the valve body.
L
DMake sure that the mounting bolts are not loose and that
the O-ring and valve body are notdamaged or positioned
incorrectly.
DIf the extent of thedamagelooks too bad for repairs to be
carried out, replace the valve body assembly.NGReplace the torque converter assembly.
Check the trouble symptoms.
Replace the engine-A/T-ECU or A/T-ECU.NG


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk

AUTOMATIC TRANSMISSION -Troubleshooting 23-52
Inspection procedure 7
N-to-D shocks, large time lag
Probable cause
If abnormalshocks or atime lag of 2 seconds or more occurs when the
selector lever is moved from N to D while theengine is idling, thecause is
probably abnormal UD clutch pressure, or a malfunction of the UD clutch, valve
body or APS.DAbnormal UD clutch pressure
DMalfunction of UD solenoid valve
DMalfunction of UD clutch system
DMalfunction of valve body
DMalfunction of APS
DMalfunction of engine-A/T-ECU <6G7>
DMalfunction of A/T-ECU<4M4>
LRefer to the Transmission Workshop Manual.
NO
MUT-
IIActuator Test
DNo.2 UD solenoid valve
OK:Sound of operation can be heardNGReplace the solenoid valve.
L
OK
When starting off
Shocks are sometimes generated.
NG
UD clutch check
L
DCheck for a problem such as burnt facing, poor piston
sealing or interference with the retainer.
NG
Code No. 11, 12, 14 APS system check (Refer to P.23-13, 14
and 15.)
Disassemble, clean and re-assemble the valve body.
L
DMake sure that the mounting bolts are not loose and that
the O-ring and valve body are notdamaged or positioned
incorrectly.
DIf the extent of thedamagelooks too bad for repairs to be
carried out, replace the valve body assembly.
OK
During shifting
Fluid pressure test (Refer to P.23-106.)
DMeasure the UD clutch fluid pressure when shifting from N
to D.
Standard value:Refer to P.23-106.MUT-
IIData List
DNo.11 APS
OK:Increases in proportion to the acceleratorpedal open-
ing angle.
YES
OK OK
UD clutch system check
L
DRemove the transmission assembly, the valve body cover
and the valve body.
DBlow air through the UD clutch oilhole in the transmission
case, and check that the piston operates to maintain
pressure.NG
Check the trouble symptoms.
Replace the engine-A/T-ECU or A/T-ECU.NG
When areshocksgenerated?


www.WorkshopManuals.co.uk


Purchased from www.WorkshopManuals.co.uk