Mitsubishi Montero (1991+). Manual — part 309

CONDITION POSSIBLE CAUSE CORRECTION

Chattering or Incorrect clutch adjustment Adjust clutch

Grabbing

Oil, grease or glaze on Disassemble and clean

facings or replace

Loose "U" joint flange See DRIVE AXLES

article

Worn input shaft spline Replace input shaft

Binding pressure plate Replace pressure plate

Binding release lever See CLUTCH article

Binding clutch disc hub Replace clutch disc

Unequal pressure plate Replace worn/misaligned

contact components

Loose/bent clutch disc Replace clutch disc

Incorrect transmission Realign transmission

alignment

Worn pressure plate, disc Replace damaged

or flywheel components

Broken or weak pressure Replace pressure

springs plate

Sticking clutch pedal Lubricate clutch pedal

& linkage

Incorrect clutch disc Replace clutch disc

facing

Engine loose in chassis Tighten all mounting

bolts

Failure to Oil or grease on clutch Clean or replace clutch

Release facings clutch disc

Incorrect release lever or See CLUTCH article

pedal adjustment

Worn or broken clutch Replace clutch disc

facings

Bent clutch disc or Replace damaged

pressure plate components

Clutch disc hub binding on Clean or replace clutch

input shaft disc and/or input shaft

Binding pilot bearing Replace pilot bearing

Sticking release bearing Replace release bearing

sleeve and/or sleeve

Binding clutch cable See CLUTCH article

Defective clutch master Replace master cylinder

Defective clutch slave Replace slave cylinder

Air in hydraulic system Bleed hydraulic system

Rattling Weak or broken release Replace spring and

lever spring check alignment

Damaged pressure plate Replace pressure plate

Broken clutch return spring Replace return spring

Worn splines on clutch disc Replace clutch disc

or input shaft and/or input shaft

Worn clutch release bearing Replace release bearing

Dry or worn pilot bearing Lubricate or replace

pilot bearing

Unequal release lever Align or replace

contact release lever

Incorrect pedal free play Adjust free play

Warped or damaged clutch Replace damaged

disc components

Slipping Pressure springs worn or Release pressure plate

Oily, greasy or worn Clean or replace clutch

facings disc

Incorrect clutch alignment Realign clutch assembly

Warped clutch disc or Replace damaged

pressure plate components

Binding release levers or Lubricate and/or

clutch pedal replace release

components

Squeaking Worn or damaged release Replace release bearing

Dry or worn pilot or Lubricate or replace

release bearing assembly

Pilot bearing turning in Replace pilot bearing

crankshaft and/or crankshaft

Worn input shaft bearing Replace bearing and

seal

Incorrect transmission Realign transmission

alignment

Dry release fork between Lubricate release fork

pivot and pivot

Heavy and/or Sticking release bearing Replace release bearing

Stiff Pedal sleeve and/or sleeve

Dry or binding clutch Lubricate and align

pedal hub components

Floor mat interference Lay mat flat in proper

with pedal area

Dry or binding ball/fork Lubricate and align

pivots components

Faulty clutch cable Replace clutch cable

Noisy Clutch Faulty interlock switch Replace interlock

Pedal switch

Self-adjuster ratchet Lubricate or replace

noise self-adjuster

Speed control interlock Lubricate or replace

switch interlock switch

Clutch Pedal Binding clutch cable See CLUTCH article

Sticks Down

Springs weak in pressure Replace pressure plate

plate

Binding in clutch linkage Lubricate and free

linkage

Noisy Dry release bearing Lubricate or replace

release bearing

Dry or worn pilot bearing Lubricate or replace

bearing

Worn input shaft bearing Replace bearing

Transmission Weak springs in pressure Replace pressure plate

Click plate

Release fork loose on ball Replace release fork

stud and/or ball stud

Oil on clutch disc damper Replace clutch disc

Broken spring in slave Replace slave cylinder

cylinder

DRIVE AXLE - NOISE DIAGNOSIS

Unrelated Noises

Some driveline trouble symptoms are also common to the

engine, transmission, wheel bearings, tires, and other parts of the

vehicle. Ensure cause of trouble actually is in the drive axle before

adjusting, repairing, or replacing any of its parts.

Non-Drive Axle Noises

A few conditions can sound just like drive axle noise and

have to be considered in pre-diagnosis. The 4 most common noises are

exhaust, tires, CV/universal joints and wheel trim rings.

In certain conditions, the pitch of the exhaust gases may

sound like gear whine. At other times, it may be mistaken for a wheel

bearing rumble.

Tires, especially radial and snow, can have a high-pitched

tread whine or roar, similar to gear noise. Also, some non-standard

tires with an unusual tread construction may emit a roar or whine.

Defective CV/universal joints may cause clicking noises or

excessive driveline play that can be improperly diagnosed as drive

axle problems.

Trim and moldings also can cause a whistling or whining

noise. Ensure none of these components are causing the noise before

disassembling the drive axle.

Gear Noise

A "howling" or "whining" noise from the ring and pinion gear

can be caused by an improper gear pattern, gear damage, or improper

bearing preload. It can occur at various speeds and driving

conditions, or it can be continuous.

Before disassembling axle to diagnose and correct gear

noise, make sure that tires, exhaust, and vehicle trim have been

checked as possible causes.

Chuckle

This is a particular rattling noise that sounds like a stick

against the spokes of a spinning bicycle wheel. It occurs while

decelerating from 40 MPH and usually can be heard until vehicle comes

to a complete stop. The frequency varies with the speed of the

vehicle.

A chuckle that occurs on the driving phase is usually caused

by excessive clearance due to differential gear wear, or by a damaged

tooth on the coast side of the pinion or ring gear. Even a very small

tooth nick or a ridge on the edge of a gear tooth is enough the cause

the noise.

This condition can be corrected simply by cleaning the gear

tooth nick or ridge with a small grinding wheel. If either gear is

damaged or scored badly, the gear set must be replaced. If metal has

broken loose, the carrier and housing must be cleaned to remove

particles that could cause damage.

Knock

This is very similar to a chuckle, though it may be louder,

and occur on acceleration or deceleration. Knock can be caused by a

gear tooth that is damaged on the drive side of the ring and pinion

gears. Ring gear bolts that are hitting the carrier casting can cause

knock. Knock can also be due to excessive end play in the axle shafts.

Clunk

Clunk is a metallic noise heard when an automatic

transmission is engaged in Reverse or Drive, or when throttle is

applied or released. It is caused by backlash somewhere in the

driveline, but not necessarily in the axle. To determine whether

driveline clunk is caused by the axle, check the total axle backlash

as follows:

1) Raise vehicle on a frame or twinpost hoist so that drive

wheels are free. Clamp a bar between axle companion flange and a part

of the frame or body so that flange cannot move.

2) On conventional drive axles, lock the left wheel to keep

it from turning. On all models, turn the right wheel slowly until it

is felt to be in Drive condition. Hold a chalk marker on side of tire

about 12" from center of wheel. Turn wheel in the opposite direction

until it is again felt to be in Drive condition.

3) Measure the length of the chalk mark, which is the total