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Mitsubishi Montero (1998+). Manual - part 66

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.

DO NOT clean release bearing assembly in solvent. Inspect hydraulic

system components for fluid leakage. Inspect cylinder dust boot for

cracks or deterioration.

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 depth from

clutch disc surface to head of rivet. Replace clutch disc if

measurement is less than .012" (.30 mm). See Fig. 4. Replace worn or

defective components as necessary.

Fig. 4: Measuring Clutch Disc (Typical)

Courtesy of Mitsubishi Motor Sales of America.

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. Tighten bolts evenly in a crisscross pattern to

specification. See TORQUE SPECIFICATIONS.

2) Clean release bearing sliding surface. Apply a light

coating 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.

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.

Fig. 5: Exploded View Of Clutch Release Bearing & Shift Arm Assembly

Courtesy of Mitsubishi Motor Sales of America.

CLUTCH MASTER CYLINDER

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