Mitsubishi Montero (1991+). Manual - part 77

         CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION

Condition                 Code                          Procedure

Binding  .................  A  ..  Require repair or replacement.

Bleeder port damaged (not

 repairable)  ............  A  ........  (1) Require replacement.

Bleeder port damaged

 (repairable)  ...........  A  .............  ( 1) Require repair.

Bleeder screw broken off

 in slave cylinder  ......  A  ........  (1) Require replacement.

Bleeder screw seized  ....  A  ........  (2) Require replacement.

Bore corroded (pitted)  ..  B  ............  Require replacement.

Bore grooved  ............  A  ............  Require replacement.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

(1) - Only required if the hydraulic system must be opened.

(2) - Seized is defined as a bleeder screw that cannot be

      removed after a practical attempt at removing it has

      been made.

         COMPANION FLANGES

         See YOKES AND SLIP YOKES.

         CONNECTORS

         See WIRING HARNESSES AND CONNECTORS.

         COOLER BYPASS VALVES

COOLER BYPASS VALVE INSPECTION

Condition                 Code                          Procedure

Inoperative  .............  A  ............  Require replacement.

Installed incorrectly  ...  A  .................  Require repair.

Leaking  .................  A  ..  Require repair or replacement.

Restricted  ..............  A  ..  Require repair or replacement.

         COOLER LINES

COOLER LINE INSPECTION

Condition                 Code                          Procedure

Abrasion damage, affecting

 structural integrity  ...  A  ..  Require repair or replacement.

Abrasion damage, not

 affecting structural

 integrity  ..............  ..  ........  No service suggested or

                                                        required.

Application incorrect  ...  B  ............  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.

Clamp corroded, not

 reusable  ...............  1  ............  Suggest replacement.

Connected incorrectly  ...  A  .................  Require repair.

Corroded, affecting

 structural integrity  ...  A  ............  Require replacement.

Corroded, not affecting

 structural integrity  ...  ..  ........  No service suggested or

                                                        required.

Cracked  .................  A  ..  Require repair or replacement.

Fitting type incorrect

 (such as compression

 fitting)  ...............  B  ............  Require replacement.

Flange leaking  ..........  A  ..  Require repair or replacement.

Insufficient clamping

 force, allowing hose to

 leak  ...................  A  ..  Require repair or replacement.

Leaking  .................  A  ..  Require repair or replacement.

Melted  ..................  1  ..  Suggest repair or replacement.

Missing  .................  C  ............  Require replacement.

Outer covering damaged to

 the extent that the inner

 fabric is visible  ......  A  ............  Require replacement.

Protective sleeves

 damaged  ................  2  .  Suggest replacement of sleeves.

Protective sleeves

 missing  ................  C  .  Require replacement of sleeves.

Restricted, affecting

 performance  ............  A  ..  Require repair or replacement.

Routed incorrectly  ......  2  .................  Require repair.

Swollen  .................  1  ............  Suggest replacement.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

Type incorrect  ..........  1  ..  Suggest repair or replacement.

         COOLERS

         See TRANSMISSION COOLERS.

         CV JOINTS

CV JOINT INSPECTION

Condition                 Code                          Procedure

Bearing, bushing or seal

 surface worn, affecting

 performance  ............  A  ..  Require repair or replacement.

Boot clamp broken  .......  A  ...  Require repair or replacement

                                                        of clamp.

Boot clamp loose  ........  A  ...  Require repair or replacement

                                                        of clamp.

Boot clamp missing  ......  C  ...  Require repair or replacement

                                                        of clamp.

Boot leaking  ............  A  .  Require replacement of CV boot.

Boot surface cracked,

 not leaking  ............  2  .  Suggest replacement of CV boot.

Cage broken  .............  A  ...  Require repair or replacement

                                                     of CV joint.

Housing damaged to the

 extent that it no longer

 performs its intended

 function  ...............  A  ...........  ( 1) Require repair or

                                         replacement of CV joint.

Housing worn to the extent

 that it no longer performs

 its intended function  ..  A  ...........  ( 1) Require repair or

                                         replacement of CV joint.

Holes elongated  .........  A  ............  Require replacement.

Internal parts binding  ..  A  ..  Require repair or replacement.

Internal parts worn  .....  A  ..  Require repair or replacement.

Lubricant missing  .......  C  ...  Require cleaning, inspection,

                                       and repacking of CV joint.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

(1) - Housing assembly may appear blue in color from normal

      manufacturing process of heat-treating the housing.

         DIP STICK TUBES

DIP STICK TUBE INSPECTION

Condition                 Code                          Procedure

Broken  ..................  A  ..  Require repair or replacement.

Checkball missing  .......  C  ..  Suggest repair or replacement.

Cracked  .................  A  ..  Require repair or replacement.

Hold down bracket

 broken  .................  A  ..  Require repair or replacement.

Hold down bracket

 missing  ................  C  ............  Require replacement.

Leaking  .................  A  ..  Require repair or replacement.

Missing  .................  C  ............  Require replacement.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

         DIP STICKS (FLUID LEVEL INDICATORS)

DIP STICK (FLUID LEVEL INDICATOR) INSPECTION

Condition                 Code                          Procedure

Application incorrect  ...  B  ............  Require replacement.

Broken  ..................  A  ............  Require replacement.

Compressed  ..............  A  ..  Require repair or replacement.

Missing  .................  C  ............  Require replacement.

Modified  ................  A  ............  Require replacement.

Stretched  ...............  A  ..  Require repair or replacement.

         DOWEL PINS, GUIDES AND PILOT HOLES

DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION

Condition                 Code                          Procedure

Application incorrect  ...  B  ..  Require repair or replacement.

Cracked  .................  A  ..  Require repair or replacement.

Distorted  ...............  A  ..  Require repair or replacement.

Missing  .................  C  ............  Require replacement.

Positioned incorrectly  ..  B  ..  Require repair or replacement.

Stepped  .................  A  ..  Require repair or replacement.

Worn to the extent that it

 no longer performs its

 intended function  ......  A  ..  Require repair or replacement.

         DRIVE SHAFT FLANGES

         See COMPANION FLANGES.

         DRIVE SHAFTS AND HALF SHAFTS

DRIVE SHAFT AND HALF SHAFT INSPECTION

Condition                 Code                          Procedure

Balance weight missing  ..  C  ..  Require repair or replacement.

Bearing cap bore

 distorted  ..............  A  ..  Require repair or replacement.

Bent  ....................  A  ............  Require replacement.

Bolt holes elongated  ....  A  ..  Require repair or replacement.

Bushing or seal surface

 worn, affecting

 performance  ............  A  ..  Require repair or replacement.

Leaking through soft yoke

 plug  ...................  A  ...  Require repair or replacement

                                               of soft yoke plug.

Out of balance  ..........  A  ..  Require repair or replacement.

Retainer strap bent  .....  A  ..........  Require replacement of

                                                  retainer strap.

Slip yoke broken  ........  A  ............  Require replacement.

Splines worn, affecting

 performance  ............  A  ............  Require replacement.

Splines worn close to

 the end of their

 useful life  ............  1  ............  Suggest replacement.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

U-bolt damaged, affecting

 performance  ............  A  .  Require replacement of U-bolts.

Yoke damaged, affecting

 performance  ............  A  ..  Require repair or replacement.

         DUST BOOTS

NOTE:    Does not include CV boots.

DUST BOOT INSPECTION

Condition                 Code                          Procedure

Cracked, not leaking  ....  1  ............  Suggest replacement.

Missing  .................  C  ............  Require replacement.

Leaking  .................  A  ..  Require repair or replacement.