Mitsubishi Montero (1991+). Manual — part 204
STRIKE OUT BUMPERS
STRIKE OUT BUMPER INSPECTION
Condition Code Procedure
Attaching hardware
broken . . . . . A . . .. Require replacement of
broken part.
Attaching hardware
corroded, affecting
structural integrity ... A . . .. Require replacement of
corroded part.
Attaching hardware
loose . . . . .. A ... Require repair or replacement
of loose part.
Attaching hardware
missing . . . . C . . .. Require replacement of
missing part.
Attaching hardware
threads damaged . . A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads.
Missing . . . . . C . . . Require replacement.
Split . . . . ... 1 . . . Suggest replacement.
STRUT RODS
STRUT ROD INSPECTION
Condition Code Procedure
Adjusting nut seized . A . . ... ( 1) Require repair or
replacement.
Attaching hardware
bent . . . . ... B ... Require repair or replacement
of bent part, if available;
otherwise, replace strut rod.
Attaching hardware
broken . . . . . A ... Require replacement of broken
part, if available; otherwise,
replace strut rod.
Attaching hardware
incorrect . . . .. A . . .. Require replacement of
incorrect part, if available;
otherwise, replace strut rod.
Attaching hardware
loose . . . . .. A ... Require repair or replacement
of loose part, if available;
otherwise, replace strut rod.
Attaching hardware
missing . . . . C .. Require replacement of missing
part, if available; otherwise,
replace strut rod.
Attaching hardware
threads damaged . . A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace strut rod.
Attaching hardware
threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads, if
available; otherwise, replace
strut rod.
Attaching (mating) hole
oversized . . . .. A ... Require repair or replacement
of frame.
Attaching point on frame
corroded, affecting
structural integrity ... A . . Require repair of frame.
Bent . . . . . A . . . Require replacement.
Mating (attaching) hole
oversized . . . .. A ... Require repair or replacement
of frame.
Threads damaged . . . A .. Require repair or replacement.
Threads stripped
(threads missing) . .. A . . . Require replacement.
(1) - Only required if an alignment is being performed.
STRUT UPPER BEARING PLATE ASSEMBLIES
NOTE: When the following guidelines indicate replacement of
bearing, only the bearing should be replaced if it is
available separately; otherwise, replace the bearing
plate assembly.
STRUT UPPER BEARING PLATE ASSEMBLY INSPECTION
Condition Code Procedure
Attaching hardware
broken . . . . . A ... Require replacement of broken
part, if available; otherwise,
replace bearing plate assembly.
Attaching hardware
loose . . . . .. A ... Require repair or replacement
of loose part, if available;
otherwise, replace bearing
plate assembly.
Attaching hardware
missing . . . . C .. Require replacement of missing
part, if available; otherwise,
replace bearing plate assembly.
Attaching hardware
threads damaged . . A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace bearing plate assembly.
Attaching hardware
threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads, if
available; otherwise, replace
bearing plate assembly.
Bearing axial or radial
movement exceeds vehicle
manufacturer’s
specifications . . . B . . . . Require replacement
of bearing.
Bearing binding . . . A . . . . Require replacement
of bearing.
Bearing missing . . . C . . . . Require replacement
of bearing.
Bearing seized . . .. A . . . . Require replacement
of bearing.
Bent . . . . . B . . . Require replacement.
Holes distorted . . . A . . . Require replacement.
Missing . . . . . C . . . Require replacement.
Severely corroded,
affecting structural
integrity . . . .. A . . . Require replacement.
SWAY BAR LINKS
SWAY BAR LINK INSPECTION
Condition Code Procedure
Attaching hardware
incorrect . . . .. A . . .. Require replacement of
incorrect part, if available;
otherwise, replace link.
Attaching hardware
loose . . . . .. A ... Require repair or replacement
of loose part, if available;
otherwise, replace link.
Attaching hardware
missing . . . . C .. Require replacement of missing
part, if available; otherwise,
replace link.
Attaching hardware
threads damaged . . A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace link.
Attaching hardware
threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads, if
available; otherwise, replace
link.
Ball and socket has
looseness (perceptible
vertical movement) . . 1 . . (1) Suggest replacement.
Ball and socket has
looseness that is
excessive . . . .. B . . (1)(2) Require replacement.
Bent . . . . . B . . . Require replacement.
Broken . . . . .. A . . . Require replacement.
Corroded, affecting
structural integrity ... A . . . Require replacement.
Grease boot cracked . . 2 . . (3) Suggest replacement.
Grease boot missing . . 2 . . (4) Suggest replacement.
Grease boot torn . . 2 . . (5) Suggest replacement.
Missing . . . . . C . . . Require replacement.
Nut on stud loose . ... A . . . . ( 6) Require repair.
Stud bent . . . ... B . . (7) Require replacement.
Stud broken . . . . A . . (7) Require replacement.
Threads damaged . . . A .. Require repair or replacement.
Threads stripped (threads
missing) . . . ... A . . (7) Require replacement.
(1) - If manufacturer’s procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and
socket movement. Use only moderate hand pressure.
(2) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural
integrity.
(3) - Cracked grease boot will allow contaminants to enter
the joint and will accelerate wear.
(4) - Lack of grease boot will allow contaminants to enter
the joint and will accelerate wear.
(5) - Torn grease boot will allow contaminants to enter the
joint and will accelerate wear.
(6) - Check for bent stud or damaged taper hole.
(7) - Check for damaged taper hole.
SWAY BARS
SWAY BAR INSPECTION
Condition Code Procedure
Attaching hardware
broken . . . . . A ... Require replacement of broken
part, if available; otherwise,
replace sway bar.
Attaching hardware
corroded, affecting
structural integrity ... A . . .. Require replacement of
corroded part, if available;
otherwise, replace sway bar.
Attaching hardware
loose . . . . .. A ... Require repair or replacement
of loose part, if available;
otherwise, replace sway bar.
Attaching hardware
missing . . . . C .. Require replacement of missing
part, if available; otherwise,
replace sway bar.
Attaching hardware
threads damaged . . A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace sway bar.
Attaching hardware
threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads, if
available; otherwise, replace
sway bar.
Bent . . . . . B . . . Require replacement.
Broken . . . . .. A . . . Require replacement.
Threads damaged . . . A .. Require repair or replacement.
Threads stripped
(threads missing) . .. A . . . Require replacement.
TIE ROD ENDS (INNER AND OUTER)
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