Mitsubishi Montero (2002-2004). Manual — part 856

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-15

ESSENTIAL SERVICE

TRANSMISSION FLUID CHECK

M1231101600156

1. Drive the vehicle until the transmission fluid temperature

rises to the normal temperature [70

− 80°C (158 − 176°F)].

NOTE: The transmission fluid temperature is measured with
scan tool MB991502 (MUT-II).
NOTE: If it takes some amount of time until the transmission
fluid reaches its normal operating temperature [70

−

80

°

C

(158

−

176

°

F)], check the transmission fluid level by refer-

ring to the left diagram.

2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque

converter and the hydraulic circuits with fluid, and then move
the selector lever to the "N" position.

4. After wiping off any dirt around the dipstick, remove the

dipstick and check the condition of the transmission fluid.
NOTE: If the transmission fluid smells as if it is burnt, it
means that the transmission fluid has been contaminated by
fine particles from the bushings and friction materials. A
transmission overhaul and cooler line flushing may be nec-
essary.

ACX00213

DATA LINK
CONNECTOR

AJ

T

AC203914

AC

U

ACCELERATOR PEDAL
POSITION SENSOR

STEERING
SHAFT

ACX02208 AF

STOPLIGHT
SWITCH

BRAKE PEDAL

V

AC100600

HOT

AB

FLUID LEVEL [mm (in)]

10 (0.4)

0 (0)

–10 (–0.4)

–20 (–0.8)

20 (0.8)

–30 (–1.2)

–40 (–1.6)

40
(104)

60
(140)

80
(176)

FLUID TEMPERATURE [˚C (˚F)]

DIPSTICK

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-16

5. Check that the transmission fluid level is at the "HOT" mark

on the dipstick. If the transmission fluid level is less than
this, add DIAMOND ATF SP III or equivalent transmission
fluid until the level reaches the "HOT" mark.
NOTE: If the transmission fluid level is too low, the oil pump
will draw in air along with the transmission fluid, which will
cause bubbles to form. If the transmission fluid level is too
high, rotating components inside the transmission will churn
the fluid and air into a foamy liquid. Both conditions (level
too low or too high) will cause the hydraulic pressure to
drop, which will result in late shifting and slipping of the
clutches and brakes.
In either case, air bubbles can interfere with normal valve,
clutch, and brake operation. Also, foaming can cause trans-
mission fluid to escape from the transmission vents where it
may be mistaken for a leak.

6. Securely insert the dipstick.

NOTE: The transmission fluid should always be replaced
under the following conditions:

.

•

When troubleshooting the transmission

•

When overhauling the transmission

•

When the transmission fluid is noticeably dirty or burnt
(driving under severe conditions)

TRANSMISSION FLUID REPLACEMENT

M1231101700153

If you have an transmission fluid changer, use it to replace the
transmission fluid. If you do not have an transmission fluid
changer, replace the transmission fluid by the following proce-
dure.
1. Disconnect the hose shown in the illustration which

connects the transmission and the oil cooler (inside the
radiator). Place a container under the hose to collect the
discharge.

CAUTION

The engine should be stopped within one minute after it is
started. If all the transmission fluid has drained out before
then, the engine should be stopped at that point.
2. Start the engine and let the transmission fluid drain out.

(Running conditions: "N" range with engine idling.)

Discharge volume: Approximately 4.0 dm

3

(4.2 quarts)

3. Remove the drain plug from the bottom of the transmission

case to drain the transmission fluid.

Discharge volume: Approximately 2.0 dm

3

(2.1 quarts)

4. Install the drain plug with a new gasket, and tighten it to the

specified torque.

Tightening torque: 39

± 5 N⋅m (29 ± 3 ft-lb)

AC000846AC

ACX01184

AB

ACX01185AB

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-17

CAUTION

Stop pouring if the full volume of transmission fluid can
not be added.
5. Add new transmission fluid (DIAMOND ATF SP III or

equivalent) through the oil filter tube.

Adding volume: Approximately 6.0 dm

3

(6.3 quarts)

6. Repeat the procedure in Step 2. (to pump out the rest of the

contaminated transmission fluid)

7. Add new transmission fluid (DIAMOND ATF SP III or

equivalent) through the oil filler tube.

Adding volume: Approximately 4.0 dm

3

(4.2 quarts)

NOTE: Check for contamination or a burnt odor. If the trans-
mission fluid is still contaminated or burnt, repeat Steps 6
and 7 before proceeding to Step 8.

8. Reconnect the hose which was disconnected in step 1

above, and firmly replace the dipstick.

9. Start the engine and run it at idle for one to two minutes.
10.Move the selector lever through all positions, and then move

it to the "N" position.

11.Check that the transmission fluid level is at the "COLD"

mark on the dipstick. If the level is less than this, add
transmission fluid.

12.Drive the vehicle until the transmission fluid temperature

rises to the normal operating temperature [70

− 80°C (158 −

176

°F)], and then check the transmission fluid level again.

The transmission fluid level must be at the "HOT" mark.
NOTE: The transmission fluid temperature is measured with
scan tool MB991502 (MUT-II).
NOTE: The "COLD" level is for reference only; the "HOT"
level should be regarded as the standard level.
NOTE: If it takes some amount of time until the transmission
fluid reaches its normal operating temperature [70

−

80

°

C

(158

−

176

°

F)], check the transmission fluid level by refer-

ring to the left diagram.

13.When the transmission fluid is less than the specified level,

add transmission fluid.
When the transmission fluid is greater than the specified
level, drain the excess fluid through the drain plug to adjust
the transmission fluid to the specified level.

14.Firmly insert the dipstick into the oil filler tube.

ACX01184

AB

AC000846AC

AC100600

HOT

AB

FLUID LEVEL [mm (in)]

10 (0.4)

0 (0)

–10 (–0.4)

–20 (–0.8)

20 (0.8)

–30 (–1.2)

–40 (–1.6)

40
(104)

60
(140)

80
(176)

FLUID TEMPERATURE [˚C (˚F)]

DIPSTICK

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-18

FLUSHING COOLERS AND TUBES

M1231104800159

Required Special Tool:

• MB995062: Flushing Tool

WARNING

•

Wear protective eyewear that meets the require-
ments of and ANSI Z87.1

− 1968 and OSHA. Wear

standard industrial rubber gloves.

•

Keep lighted cigarettes, sparks, flames, and other
ignition sources away from the area to prevent the
ignition of combustible liquids and gases. Keep a
class B fire extinguisher in the area where the
flushing tool will be used. Keep the area well venti-
lated. Do not let flushing solvent come in contact
with eyes or skin. If it does, flush with water for 15
to 20 seconds. Remove contaminated clothing and
wash affected skin with soap and water. Seek med-
ical attention.

When a transmission failure has contaminated the transmission
fluid, the oil cooler(s) must be flushed. The cooler by-pass
valve in the transmission must also be replaced. The torque
converter must also be replaced with an exchange unit. This
will ensure that metal particles or sludged transmission fluid are
not later transferred back into the reconditioned (or replaced)
transmission. There are two different procedures for flushing
coolers and lines. The recommended procedure is to use spe-
cial tool MB995062 Flushing Tool. The other procedure is to
use a hand suction gun and mineral spirits.
1. Remove the cover plate filler plug on special tool

MB995062. Fill the reservoir 1/2 to 3/4 full with fresh flushing
solution. Flushing solvents are petroleum based solutions
generally used to clean transmission components. Do not
use solvents containing acids, water, gasoline, or any other
corrosive liquids.

2. Reinstall the filler plug on special tool MB995062.
3. Verify that the pump power switch is turned "OFF." Connect

the red alligator clip to the positive battery terminal. Connect
the black alligator clip to a good ground.

4. Disconnect the cooler lines at the transmission.

NOTE: When flushing the transmission cooler and lines,
always reverse flush.

5. Connect the BLUE pressure line to the OUTLET line (from

cooler.) cooler line.

6. Connect the CLEAR return line to the INLET line (to cooler.)

cooler line.

7. Turn the pump "ON" for two to three minutes to flush the

cooler(s) and lines. Monitor the pressure readings. Clear the
return lines. Pressure readings should stabilize below 138
kPa (20 psi) for vehicles equipped with a single cooler and
208 kPa (30 psi) for vehicles equipped with dual coolers. If
flow is intermittent or exceeds these pressures, replace the
cooler(s).

ACX02073AB

FROM COOLER

TO COOLER