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Mitsubishi Montero (1998+). Manual - part 67

Removal & Installation

1) Drain master cylinder. Remove cotter pin, washer and

clevis pin. Disconnect push rod from clutch pedal. Remove and plug

hydraulic line at clutch master cylinder.

2) Remove retaining nuts, clutch master cylinder and gasket.

To install, reverse removal procedure. Apply grease to clevis pin

before installing. Fill reservoir and bleed clutch system. See

BLEEDING CLUTCH HYDRAULIC SYSTEM.

CLUTCH RELEASE CYLINDER

Removal & Installation

Remove and plug hydraulic line at release cylinder. Remove

cylinder-to-transmission bolts. Remove clutch release cylinder. To

install, reverse removal procedure. Apply grease to push rod-to-

release fork contact area. Bleed clutch system. See

BLEEDING CLUTCH HYDRAULIC SYSTEM.

BLEEDING CLUTCH HYDRAULIC SYSTEM

Attach hose to bleeder fitting located on clutch release

cylinder, next to hydraulic line. Submerge other end of hose in

container half full of clean brake fluid. Fill reservoir with brake

fluid. Open bleeder fitting. Have assistant press clutch pedal to full

release position. Close bleeder fitting. Release clutch pedal. Repeat

until air bubbles no longer emerge from hose. Refill reservoir.

OVERHAUL

CLUTCH MASTER CYLINDER

NOTE: DO NOT disassemble piston assembly.

Disassembly

Remove piston stop ring, damper and push rod assembly. See

Fig. 6. Remove piston assembly. Note position of reservoir band for

reassembly reference. Remove reservoir.

Inspection & Reassembly

Inspect components for corrosion, scoring or damage. Replace

if necessary. Apply brake fluid to components during reassembly. On

Montero, adjust clutch master cylinder push rod to 5.90" (150 mm). On

Montero Sport, push rod adjustment is correct after adjusting clutch

pedal free play and pedal height. See CLUTCH PEDAL FREE PLAY and

CLUTCH PEDAL HEIGHT under ADJUSTMENTS. To reassemble, reverse

disassembly procedure. Ensure piston moves freely in bore.

Fig. 6: Exploded View Of Clutch Master Cylinder (Typical)

Courtesy of Mitsubishi Motor Sales of America.

CLUTCH RELEASE CYLINDER

Disassembly

Remove valve plate and spring. See Fig. 7. Remove push rod

and boot. Cover piston assembly opening with a rag. Slowly apply air

pressure to hydraulic line opening to force piston from body.

Inspection & Reassembly

Inspect components for corrosion, scoring or damage. Replace

if necessary. Apply brake fluid to components during reassembly. To

reassemble, reverse disassembly procedure. Ensure piston moves freely

in bore.

Fig. 7: Exploded View Of Clutch Release Cylinder (Typical)

Courtesy of Mitsubishi Motor Sales of America.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)

Clutch Pedal Position Switch Adjusting Nut Or Bolt ......... 10 (13)

Bellhousing-To-Engine Mounting Bolt

Montero

10 x 40 mm ............................................. 26 (36)

10 x 55 mm ............................................. 22 (31)

12 x 40 mm ............................................. 54 (75)

12 x 55 mm ............................................. 65 (90)

Montero Sport

2WD .................................................... 19 (26)

4WD .................................................... 55 (75)

Clutch Master Cylinder Mounting Nut ........................ 10 (13)

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)

COMPUTER RELEARN PROCEDURES

1998 Mitsubishi Montero

GENERAL INFORMATION

Computer Relearn Procedures

All Models

* PLEASE READ THIS FIRST *

The following general procedures are to be used if

driveability problems are encountered after power loss or battery has

been disconnected. These procedures may provide an aid in eliminating

these problems.

To reduce the possibility of complaints, after any service

which requires battery power to be disconnected, vehicle should be

road tested.

COMPUTER RELEARN PROCEDURES

Vehicles equipped with engine or transmission computers may

require a relearn procedure after vehicle battery is disconnected.

Many vehicle computers memorize and store vehicle operation patterns

for optimum driveability and performance. When vehicle battery is

disconnected, this memory is lost. The computer will use default data

until new data from each key start is stored. As computer memorizes

vehicle operation for each new key start, driveability is restored.

Vehicle computers may memorize vehicles operation patterns for 40 of

more key starts.

Customers often complain of driveability problems during

relearn stage because vehicle acts differently then before being

serviced. Depending on type and make of vehicle and how it is

equipped, the following complaints (driveability problems) may exist:

* Harsh Or Poor Shift Quality

* Rough Or Unstable Idle

* Hesitation Or Stumble

* Rich Or Lean Running

* Poor Fuel Mileage

These symptoms and complaints should disappear after a number

of drive cycles have been memorized. To reduce the possibility of

complaints, after any service which requires battery power to be

disconnected, vehicle should be road tested. If a specific relearn

procedure is not available, the following procedure may be used:

Automatic Transmission

* Set parking brake, start engine in "P" or "N" position.

Warm-up vehicle to normal operating temperature or until

cooling fan cycles.

* Allow vehicle to idle for one minute in "N" position. Select

"D" and allow engine to idle for one minute.

* Accelerate at normal throttle position (20-50%) until vehicle

shifts into top gear.

* Cruise at light to medium throttle.

* Decelerate to a stop, allowing vehicle to downshift, and use

brakes normally.

* Process may be repeated as necessary.

Manual Transmission

Content .. 65 66 67 68 ..