Mitsubishi Montero (1991+). Manual — part 77

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION

Condition Code Procedure

Binding . . . . . A .. Require repair or replacement.

Bleeder port damaged (not

repairable) . . . A . . (1) Require replacement.

Bleeder port damaged

(repairable) . . ... A . . . . ( 1) Require repair.

Bleeder screw broken off

in slave cylinder . .. A . . (1) Require replacement.

Bleeder screw seized . A . . (2) Require replacement.

Bore corroded (pitted) .. B . . . Require replacement.

Bore grooved . . . A . . . Require replacement.

Threads damaged . . . A .. Require repair or replacement.

Threads stripped (threads

missing) . . . ... A . . . Require replacement.

(1) - Only required if the hydraulic system must be opened.

(2) - Seized is defined as a bleeder screw that cannot be

removed after a practical attempt at removing it has

been made.

COMPANION FLANGES

See YOKES AND SLIP YOKES.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

COOLER BYPASS VALVES

COOLER BYPASS VALVE INSPECTION

Condition Code Procedure

Inoperative . . . . A . . . Require replacement.

Installed incorrectly ... A . . . . . Require repair.

Leaking . . . . . A .. Require repair or replacement.

Restricted . . . .. A .. Require repair or replacement.

COOLER LINES

COOLER LINE INSPECTION

Condition Code Procedure

Abrasion damage, affecting

structural integrity ... A .. Require repair or replacement.

Abrasion damage, not

affecting structural

integrity . . . .. .. . . No service suggested or

required.

Application incorrect ... B . . . Require replacement.

Attaching hardware

broken . . . . . A ... Require repair or replacement

of hardware.

Attaching hardware

missing . . . . C . . .. Require replacement of

hardware.

Attaching hardware not

functioning . . . A ... Require repair or replacement

of hardware.

Clamp corroded, not

reusable . . . ... 1 . . . Suggest replacement.

Connected incorrectly ... A . . . . . Require repair.

Corroded, affecting

structural integrity ... A . . . Require replacement.

Corroded, not affecting

structural integrity ... .. . . No service suggested or

required.

Cracked . . . . . A .. Require repair or replacement.

Fitting type incorrect

(such as compression

fitting) . . . ... B . . . Require replacement.

Flange leaking . . .. A .. Require repair or replacement.

Insufficient clamping

force, allowing hose to

leak . . . . ... A .. Require repair or replacement.

Leaking . . . . . A .. Require repair or replacement.

Melted . . . . .. 1 .. Suggest repair or replacement.

Missing . . . . . C . . . Require replacement.

Outer covering damaged to

the extent that the inner

fabric is visible . .. A . . . Require replacement.

Protective sleeves

damaged . . . . 2 . Suggest replacement of sleeves.

Protective sleeves

missing . . . . C . Require replacement of sleeves.

Restricted, affecting

performance . . . A .. Require repair or replacement.

Routed incorrectly . .. 2 . . . . . Require repair.

Swollen . . . . . 1 . . . Suggest replacement.

Threads damaged . . . A .. Require repair or replacement.

Threads stripped (threads

missing) . . . ... A . . . Require replacement.

Type incorrect . . .. 1 .. Suggest repair or replacement.

COOLERS

See TRANSMISSION COOLERS.

CV JOINTS

CV JOINT INSPECTION

Condition Code Procedure

Bearing, bushing or seal

surface worn, affecting

performance . . . A .. Require repair or replacement.

Boot clamp broken . ... A ... Require repair or replacement

of clamp.

Boot clamp loose . . A ... Require repair or replacement

of clamp.

Boot clamp missing . .. C ... Require repair or replacement

of clamp.

Boot leaking . . . A . Require replacement of CV boot.

Boot surface cracked,

not leaking . . . 2 . Suggest replacement of CV boot.

Cage broken . . . . A ... Require repair or replacement

of CV joint.

Housing damaged to the

extent that it no longer

performs its intended

function . . . ... A . . ... ( 1) Require repair or

replacement of CV joint.

Housing worn to the extent

that it no longer performs

its intended function .. A . . ... ( 1) Require repair or

replacement of CV joint.

Holes elongated . . . A . . . Require replacement.

Internal parts binding .. A .. Require repair or replacement.

Internal parts worn . . A .. Require repair or replacement.

Lubricant missing . ... C ... Require cleaning, inspection,

and repacking of CV joint.

Threads damaged . . . A .. Require repair or replacement.

Threads stripped (threads

missing) . . . ... A . . . Require replacement.

(1) - Housing assembly may appear blue in color from normal

manufacturing process of heat-treating the housing.

DIP STICK TUBES

DIP STICK TUBE INSPECTION

Condition Code Procedure

Broken . . . . .. A .. Require repair or replacement.

Checkball missing . ... C .. Suggest repair or replacement.

Cracked . . . . . A .. Require repair or replacement.

Hold down bracket

broken . . . . . A .. Require repair or replacement.

Hold down bracket

missing . . . . C . . . Require replacement.

Leaking . . . . . A .. Require repair or replacement.

Missing . . . . . C . . . Require replacement.

Threads damaged . . . A .. Require repair or replacement.

Threads stripped (threads

missing) . . . ... A . . . Require replacement.

DIP STICKS (FLUID LEVEL INDICATORS)

DIP STICK (FLUID LEVEL INDICATOR) INSPECTION

Condition Code Procedure

Application incorrect ... B . . . Require replacement.

Broken . . . . .. A . . . Require replacement.

Compressed . . . .. A .. Require repair or replacement.

Missing . . . . . C . . . Require replacement.

Modified . . . . A . . . Require replacement.

Stretched . . . ... A .. Require repair or replacement.

DOWEL PINS, GUIDES AND PILOT HOLES

DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION

Condition Code Procedure

Application incorrect ... B .. Require repair or replacement.

Cracked . . . . . A .. Require repair or replacement.

Distorted . . . ... A .. Require repair or replacement.

Missing . . . . . C . . . Require replacement.

Positioned incorrectly .. B .. Require repair or replacement.

Stepped . . . . . A .. Require repair or replacement.

Worn to the extent that it

no longer performs its

intended function . .. A .. Require repair or replacement.

DRIVE SHAFT FLANGES

See COMPANION FLANGES.

DRIVE SHAFTS AND HALF SHAFTS

DRIVE SHAFT AND HALF SHAFT INSPECTION

Condition Code Procedure

Balance weight missing .. C .. Require repair or replacement.

Bearing cap bore

distorted . . . .. A .. Require repair or replacement.

Bent . . . . . A . . . Require replacement.

Bolt holes elongated . A .. Require repair or replacement.

Bushing or seal surface

worn, affecting

performance . . . A .. Require repair or replacement.

Leaking through soft yoke

plug . . . . ... A ... Require repair or replacement

of soft yoke plug.

Out of balance . . .. A .. Require repair or replacement.

Retainer strap bent . . A . . .. Require replacement of

retainer strap.

Slip yoke broken . . A . . . Require replacement.

Splines worn, affecting

performance . . . A . . . Require replacement.

Splines worn close to

the end of their

useful life . . . 1 . . . Suggest replacement.

Threads damaged . . . A .. Require repair or replacement.

Threads stripped (threads

missing) . . . ... A . . . Require replacement.

U-bolt damaged, affecting

performance . . . A . Require replacement of U-bolts.

Yoke damaged, affecting

performance . . . A .. Require repair or replacement.

DUST BOOTS

NOTE: Does not include CV boots.

DUST BOOT INSPECTION

Condition Code Procedure

Cracked, not leaking . 1 . . . Suggest replacement.

Missing . . . . . C . . . Require replacement.

Leaking . . . . . A .. Require repair or replacement.