Mitsubishi Montero (1998+). Manual - part 353

CONDITION         POSSIBLE CAUSE               CORRECTION

Chattering or     Incorrect clutch adjustment  Adjust clutch

Grabbing

                  Oil, grease or glaze on      Disassemble and clean

                  facings                      or  replace

                  Loose "U" joint flange       See DRIVE AXLES

                                               article

                  Worn input shaft spline      Replace input shaft

                  Binding pressure plate       Replace pressure plate

                  Binding release lever        See CLUTCH article

                  Binding clutch disc hub      Replace clutch disc

                  Unequal pressure plate       Replace worn/misaligned

                  contact                      components

                  Loose/bent clutch disc       Replace clutch disc

                  Incorrect transmission       Realign transmission

                  alignment

                  Worn pressure plate, disc    Replace damaged

                  or flywheel                  components

                  Broken or weak pressure      Replace pressure

                  springs                      plate

                  Sticking clutch pedal        Lubricate clutch pedal

                                               & linkage

                  Incorrect clutch disc        Replace clutch disc

                  facing

                  Engine loose in chassis      Tighten all mounting

                                               bolts

Failure to        Oil or grease on clutch      Clean or replace clutch

Release           facings                      clutch disc

                  Incorrect release lever or   See CLUTCH article

                  pedal adjustment

                  Worn or broken clutch        Replace clutch disc

                  facings

                  Bent clutch disc or          Replace damaged

                  pressure plate               components

                  Clutch disc hub binding on   Clean or replace clutch

                  input shaft                  disc and/or input shaft

                  Binding pilot bearing        Replace pilot bearing

                  Sticking release bearing     Replace release bearing

                  sleeve                       and/or sleeve

                  Binding clutch cable         See CLUTCH article

                  Defective clutch master      Replace master cylinder

                  Defective clutch slave       Replace slave cylinder

                  Air in hydraulic system      Bleed hydraulic system

Rattling          Weak or broken release       Replace spring and

                  lever spring                 check alignment

                  Damaged pressure plate       Replace pressure plate

                  Broken clutch return spring  Replace return spring

                  Worn splines on clutch disc  Replace clutch disc

                  or input shaft               and/or input shaft

                  Worn clutch release bearing  Replace release bearing

                  Dry or worn pilot bearing    Lubricate or replace

                                               pilot bearing

                  Unequal release lever        Align or replace

                  contact                      release lever

                  Incorrect pedal free play    Adjust free play

                  Warped or damaged clutch     Replace damaged

                  disc                         components

Slipping          Pressure springs worn or     Release pressure plate

                  Oily, greasy or worn         Clean or replace clutch

                  facings                      disc

                  Incorrect clutch alignment   Realign clutch assembly

                  Warped clutch disc or        Replace damaged

                  pressure plate               components

                  Binding release levers or    Lubricate and/or

                  clutch pedal                 replace release

                                               components

Squeaking         Worn or damaged release      Replace release bearing

                  Dry or worn pilot or         Lubricate or replace

                  release bearing              assembly

                  Pilot bearing turning in     Replace pilot bearing

                  crankshaft                   and/or crankshaft

                  Worn input shaft bearing     Replace bearing and

                                               seal

                  Incorrect transmission       Realign transmission

                  alignment

                  Dry release fork between     Lubricate release fork

                  pivot                        and pivot

Heavy and/or      Sticking release bearing     Replace release bearing

Stiff Pedal       sleeve                       and/or sleeve

                  Dry or binding clutch        Lubricate and align

                  pedal hub                    components

                  Floor mat interference       Lay mat flat in proper

                  with pedal                   area

                  Dry or binding ball/fork     Lubricate and align

                  pivots                       components

                  Faulty clutch cable          Replace clutch cable

Noisy Clutch      Faulty interlock switch      Replace interlock

Pedal                                          switch

                  Self-adjuster ratchet        Lubricate or replace

                  noise                        self-adjuster

                  Speed control interlock      Lubricate or replace

                  switch                       interlock switch

Clutch Pedal      Binding clutch cable         See CLUTCH article

Sticks Down

                  Springs weak in pressure     Replace pressure plate

                  plate

                  Binding in clutch linkage    Lubricate and free

                                               linkage

Noisy             Dry release bearing          Lubricate or replace

                                               release  bearing

                  Dry or worn pilot bearing    Lubricate or replace

                                               bearing

                  Worn input shaft bearing     Replace  bearing

Transmission      Weak springs in pressure     Replace pressure plate

Click             plate

                  Release fork loose on ball   Replace release fork

                  stud                         and/or ball stud

                  Oil on clutch disc damper    Replace clutch disc

                  Broken spring in slave       Replace slave cylinder

                  cylinder

         DRIVE AXLE - NOISE DIAGNOSIS

         Unrelated Noises

         Some driveline trouble symptoms are also common to the

engine, transmission, wheel bearings, tires, and other parts of the

vehicle. Ensure cause of trouble actually is in the drive axle before

adjusting, repairing, or replacing any of its parts.

         Non-Drive Axle Noises

         A few conditions can sound just like drive axle noise and

have to be considered in pre-diagnosis. The 4 most common noises are

exhaust, tires, CV/universal joints and wheel trim rings.

         In certain conditions, the pitch of the exhaust gases may

sound like gear whine. At other times, it may be mistaken for a wheel

bearing rumble.

         Tires, especially radial and snow, can have a high-pitched

tread whine or roar, similar to gear noise. Also, some non-standard

tires with an unusual tread construction may emit a roar or whine.

         Defective CV/universal joints may cause clicking noises or

excessive driveline play that can be improperly diagnosed as drive

axle problems.

         Trim and moldings also can cause a whistling or whining

noise. Ensure none of these components are causing the noise before

disassembling the drive axle.

         Gear Noise

         A "howling" or "whining" noise from the ring and pinion gear

can be caused by an improper gear pattern, gear damage, or improper

bearing preload. It can occur at various speeds and driving

conditions, or it can be continuous.

         Before disassembling axle to diagnose and correct gear

noise, make sure that tires, exhaust, and vehicle trim have been

checked as possible causes.

         Chuckle

         This is a particular rattling noise that sounds like a stick

against the spokes of a spinning bicycle wheel. It occurs while

decelerating from 40 MPH and usually can be heard until vehicle comes

to a complete stop. The frequency varies with the speed of the

vehicle.

         A chuckle that occurs on the driving phase is usually caused

by excessive clearance due to differential gear wear, or by a damaged

tooth on the coast side of the pinion or ring gear. Even a very small

tooth nick or a ridge on the edge of a gear tooth is enough the cause

the noise.

         This condition can be corrected simply by cleaning the gear

tooth nick or ridge with a small grinding wheel. If either gear is

damaged or scored badly, the gear set must be replaced. If metal has

broken loose, the carrier and housing must be cleaned to remove

particles that could cause damage.

         Knock

         This is very similar to a chuckle, though it may be louder,

and occur on acceleration or deceleration. Knock can be caused by a

gear tooth that is damaged on the drive side of the ring and pinion

gears. Ring gear bolts that are hitting the carrier casting can cause

knock. Knock can also be due to excessive end play in the axle shafts.

         Clunk

         Clunk is a metallic noise heard when an automatic

transmission is engaged in Reverse or Drive, or when throttle is

applied or released. It is caused by backlash somewhere in the

driveline, but not necessarily in the axle. To determine whether

driveline clunk is caused by the axle, check the total axle backlash

as follows:

         1) Raise vehicle on a frame or twinpost hoist so that drive

wheels are free. Clamp a bar between axle companion flange and a part

of the frame or body so that flange cannot move.

         2) On conventional drive axles, lock the left wheel to keep

it from turning. On all models, turn the right wheel slowly until it

is felt to be in Drive condition. Hold a chalk marker on side of tire

about 12" from center of wheel. Turn wheel in the opposite direction

until it is again felt to be in Drive condition.

         3) Measure the length of the chalk mark, which is the total