Mitsubishi Montero (1998+). Manual — part 65

CLUTCH

1998 Mitsubishi Montero

1997-98 CLUTCHES

Mitsubishi RWD

Montero, Montero Sport

DESCRIPTION

Clutch system uses diaphragm spring, single-disc type

clutches. Clutch is hydraulically operated.

ADJUSTMENTS

CLUTCH PEDAL FREE PLAY

1) Depress clutch pedal by hand until resistance is felt.

Measure clutch pedal free play. See CLUTCH PEDAL SPECIFICATIONS table.

See Fig. 1.

2) If pedal free play needs to be adjusted, loosen lock nut

on clutch master cylinder push rod and rotate push rod to obtain

correct free play. Tighten lock nut. See Fig. 1. If depressed free

play cannot be adjusted, bleed system and inspect hydraulic and clutch

components.

CLUTCH PEDAL HEIGHT

1) Measure distance between face of clutch pedal and floor

board. See CLUTCH PEDAL SPECIFICATIONS table. See Fig. 1. To adjust

pedal height, disconnect clutch switch connector (if equipped).

2) Loosen master cylinder push rod lock nut. Rotate stopper,

clutch switch or clutch master cylinder push rod until correct pedal

height is obtained.

CLUTCH PEDAL SPECIFICATIONS

Application In. (mm)

Montero

Free Play . . . . . . . . . . . .24-.51 (6-13)

Pedal Height

Pedal Depressed (1) . . . . . . . . ... 1.4 (35)

Pedal Released . . . . . . . ... 7.3-7.5 (185-190)

Montero Sport

Free Play . . . . . . . . . . . .24-.51 (6-13)

Pedal Height

Pedal Depressed (1) . . . . . . . . ... 2.2 (56)

Pedal Released . . . . . . . . . ... 7.0 (178)

(1) - Specification given is minimum distance.

Fig. 1: Measuring Pedal Free Play & Height (Typical)

Courtesy of Mitsubishi Motor Sales of America.

CLUTCH PEDAL INTERLOCK SWITCH

1) Check and adjust pedal height and free play. See

CLUTCH PEDAL HEIGHT and

CLUTCH PEDAL FREE PLAY. See Fig. 1. Measure clutch pedal full stroke.

Full stroke should be 5.72" (145 mm). If full stroke is out of

tolerance, adjust stroke by turning clutch master cylinder push rod.

See Fig. 2.

2) Measure clearance "A" with clutch pedal fully depressed

(full stroke). See Fig. 2. Clearance "A" should be .177-.217" (4.5-5.5

mm). If clearance is out of tolerance, adjust by loosening interlock

switch lock nut and turning interlock switch in appropriate direction.

When clearance "A" is correct, tighten lock nut.

Fig. 2: Adjusting Interlock Switch (Montero Shown)

Courtesy of Mitsubishi Motor Sales of America.

TESTING

CLUTCH PEDAL DEPRESSED HEIGHT

Depress clutch pedal to floor. Measure distance between face

of clutch pedal and floor board. If depressed pedal height is not as

specified, bleed system and inspect hydraulic and clutch components.

See CLUTCH PEDAL SPECIFICATIONS table.

CLUTCH PEDAL INTERLOCK SWITCH

1) Place transmission in Neutral and apply parking brake.

Turn ignition switch to START position with clutch pedal not

depressed. Engine should not crank. If engine cranks, adjust or

replace interlock switch.

2) Disconnect interlock switch connector. Interlock switch

connector is located at clutch pedal. Depress and release interlock

switch. Using ohmmeter, check continuity between interlock switch

terminals. If continuity exists with interlock switch depressed and

does not exist with switch released, switch is okay. Adjust or replace

as necessary.

REMOVAL & INSTALLATION

CLUTCH ASSEMBLY

Removal (2WD Models)

1) Disconnect negative battery cable. Remove shift knob, dust

cover retaining plate, gaskets, stopper plate and control lever

assembly. Raise and support vehicle.

2) Remove front exhaust pipe. Drain transmission fluid. Index

mark drive shaft flange and remove drive shaft.

3) Disconnect back-up light switch connector, speedometer

cable connection and exhaust pipe mounting bracket. Remove lower

bellhousing cover. Disconnect clutch cable from clutch lever.

4) Support transmission with jack. Remove rear engine mount

nuts and bolts from transmission. Remove crossmember with rear engine

mount. Remove remaining bellhousing bolts, move transmission toward

rear and lower from vehicle.

5) If reusing pressure plate, index mark pressure plate to

flywheel for installation reference. Install 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.

Inspection

1) Check release bearing and release fork for damage or wear.

DO NOT clean release bearing assembly in solvent.

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 distance

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

distance is less than .012" (.30 mm). Replace worn or defective

components as necessary. See Fig. 4.

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. If reusing pressure plate, ensure index marks are

aligned. Tighten bolts evenly in a crisscross pattern to

specification. See TORQUE SPECIFICATIONS. See Fig. 3.

2) Clean release bearing sliding surface. DO NOT clean