Mitsubishi Montero (2002-2004). Manual — part 517

SPECIFICATIONS

TSB Revision

CHASSIS ELECTRICAL

54A-239

<HEADLIGHT>

<FOG LIGHT>

SEALANT

M1543000500191

<COMBINATION METER>

Combination mete resistance
(terminal number)

Power supply and ground (67-25)

Approximately 1 M or more

Power supply and ground (67-11)

Approximately 1 M or more

IG power supply and ground (62-
25)

Approximately 1 M or more

IG power supply and ground (62-11) Approximately 1 M or more
Battery power supply and fuel gage
(67-63)

Approximately 1 M or more

IG power supply and fuel gage (62-
63)

Approximately 1 M or more

Fuel gauge and ground (63-25)

Approximately 180

Fuel gauge and ground (63-11)

Approximately 180

Battery power supply and engine
coolant temperature (67-64)

Approximately 1 M or more

IG power supply and engine coolant
temperature (62-64)

Approximately 1 M or more

Engine coolant temperature and
ground (64-25)

Approximately 210

Engine coolant temperature and
ground (64-11)

Approximately 210

ITEM

STANDARD VALUE

ITEM

STANDARD VALUE

LIMIT

Headlight aiming
(Vertical direction)

53 mm (2.1 inches) (0.4

°)

below horizontal (H)

Standard value

± 50 mm (2.0

inches) (

± 0.38°)

Headlight intensity cd (at high-beam)

-

40,000 or more {when a screen
is set 18.3 m (60 feet) ahead of
the vehicles}

ITEM

STANDARD VALUE

LIMIT

Fog light aiming
(Vertical direction)

Top of the hot zone should be
101 mm (4.0 inches) below
the fog light center (equivalent
to the fog light beam angle of
0.76

°).

Top of the hot zone should be at
most 152 mm (6.0 inches)
below the fog light center
(equivalent to the fog light beam
angle of 1.14

°).

ITEM

SPECIFIED SEALANT

REMARK

Engine coolant temperature gauge
unit threaded portion

3M

ä AAD part No. 8731, Loctite â242

or equivalent

Drying sealant

NOTES

23B-1

GROUP 23B

CONTENTS

GENERAL INFORMATION . . . . . . . .

23B-3

SPECIAL TOOLS. . . . . . . . . . . . . . . .

23B-9

TRANSMISSION AND TRANSFER. .

23B-14

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-14

TRANSFER CASE ADAPTER. . . . . .

23B-16

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-16

TRANSMISSION . . . . . . . . . . . . . . . .

23B-18

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-18

REVERSE AND OVERDRIVE
CLUTCHES . . . . . . . . . . . . . . . . . . . .

23B-67

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-67

SECOND BRAKE. . . . . . . . . . . . . . . .

23B-71

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-71

LOW REVERSE ANNULUS GEAR . .

23B-72

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-72

CENTER SUPPORT. . . . . . . . . . . . . .

23B-74

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-74

UNDERDRIVE CLUTCH . . . . . . . . . .

23B-76

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-76

VALVE BODY . . . . . . . . . . . . . . . . . . .

23B-80

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-80

DIRECT ANNURAS GEAR. . . . . . . . .

23B-89

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-89

DIRECT CLUTCH . . . . . . . . . . . . . . . .

23B-91

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-91

OUTPUTSHAFT SUPPORT . . . . . . . .

23B-94

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-94

TRANSFER . . . . . . . . . . . . . . . . . . . . .

23B-95

DISASSEMBLY AND ASSEMBLY
<PART TIME 4WD> . . . . . . . . . . . . . . . . . .

23B-95

DISASSEMBLY AND ASSEMBLY
<SUPER SELECT 4WD> . . . . . . . . . . . . . .

23B-103

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

23B-115

TRANSFER CASE PLATE . . . . . . . . .

23B-115

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-115

INPUT GEAR . . . . . . . . . . . . . . . . . . .

23B-117

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-117

COUNTERSHAFT GEAR . . . . . . . . . .

23B-118

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-118

Continued on next page

23B-2

REAR OUTPUT SHAFT. . . . . . . . . . .

23B-121

DISASSEMBLY AND ASSEMBLY
<PART TIME 4WD> . . . . . . . . . . . . . . . . . .

23B-121

DISASSEMBLY AND ASSEMBLY
<SUPER SELECT 4WD> . . . . . . . . . . . . . .

23B-125

FRONT OUTPUT SHAFT. . . . . . . . . .

23B-127

DISASSEMBLY AND ASSEMBLY
<PART TIME 4WD> . . . . . . . . . . . . . . . . . .

23B-127

DISASSEMBLY AND ASSEMBLY
<SUPER SELECT 4WD> . . . . . . . . . . . . . .

23B-128

TRANSFER DRIVE SHAFT . . . . . . . .

23B-130

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-130

SHIFTRAIL DRIVE GEAR . . . . . . . . .

23B-132

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-132

2-4 SHIFT RAIL/H-L SHIFT RAIL. . . .

23B-133

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-133

SPECIFICATIONS . . . . . . . . . . . . . . .

23B-134

TORQUE SPECIFICATION. . . . . . . . . . . . .

23B-134

GENERAL SPECIFICATIONS . . . . . . . . . .

23B-135

SERVICE SPECIFICATIONS . . . . . . . . . . .

23B-136

VALVE BODY SPRING IDENTIFICATION .

23B-137

ADJUSTING PLATE, SNAP RING AND
SPACERS . . . . . . . . . . . . . . . . . . . . . . . . . .

23B-137

SEALANTS AND ADHESIVES . . . . . . . . . .

23B-142