Mitsubishi Montero (1991+). Manual - part 295

specification, use the following trouble shooting guide.

      *  Hydraulic Pressure High In All Ranges

         Check throttle cable adjustment. If adjustment is okay, check

         for throttle valve or regulator valve failure.

      *  Hydraulic Pressure Low In All Ranges

         Check throttle cable adjustment. If adjustment is okay, check

         for throttle valve, regulator valve, transmission oil pump or

         overdrive clutch failure.

      *  Hydraulic Pressure Low In Drive Position

         Check for fluid leaks in Drive hydraulic circuit. Check for

         forward clutch or overdrive clutch failure.

      *  Hydraulic Pressure Low In Reverse Position

         Check for fluid leaks in Reverse hydraulic circuit. Check for

         transmission No. 3 brake failure, forward clutch failure or

         overdrive clutch failure.

         LINE PRESSURE (PICKUP)

         1) Incorrect throttle pressure setting will cause incorrect

line pressure readings even though line pressure adjustment is

correct. Always inspect and correct throttle pressure adjustment

before adjusting line pressure.

         2) Approximate adjustment, measured from valve body to inner

edge of adjusting nut, is 15/16". However, due to manufacturing

tolerances, adjustment can be varied to obtain correct line pressure.

         3) Adjusting screw may be turned with an Allen wrench. One

complete turn of adjusting screw changes closed throttle line pressure

approximately 1 2/3 psi. Turn adjusting screw counterclockwise to

increase pressure or clockwise to decrease pressure.

         THROTTLE PRESSURE (PICKUP)

         1) Throttle pressures cannot be accurately tested. If a

malfunction exists, adjustment should be measured.

         2) Insert Gauge Pin (C-3763) between throttle lever cam and

kickdown valve. Push in on tool to compress kickdown valve against its

spring.

         3) As force is being exerted to compress spring, turn

throttle lever screw with Allen wrench until head of screw touches

throttle lever tang with gauge pin, and throttle valve bottoms. Ensure

adjustment is made with spring fully compressed and valve bottomed in

valve body.

         KICKDOWN BAND

         PICKUP

         1) Locate kickdown band adjusting screw on left side of

transmission case. Loosen lock nut, and back off nut 5 turns. Ensure

adjusting screw turns freely in transmission case.

         2) Using torque wrench, tighten adjusting screw to 72 INCH

lbs. (8 N.m). Back off adjusting screw 2 7/8 turns. Hold adjuster

screw in this position, and tighten lock nut to 30 ft. lbs. (41 N.m).

         LOW-REVERSE BAND

         PICKUP

         1) Raise vehicle, drain transmission, and remove oil pan.

Loosen adjusting screw lock nut, and back off nut 5 turns. Ensure

adjusting screw turns freely in lever.

         2) Using torque wrench, tighten band adjusting screw to 30

INCH lbs. (3.5 N.m). Back off adjusting screw 6 turns. Hold adjusting

screw in this position, and tighten lock nut to 25 ft. lbs. (34 N.m).

         3) Reinstall oil pan using new gasket. Tighten pan bolts to

150 INCH lbs. (17 N.m). Refill with specified transmission fluid.

         KICKDOWN SERVO

         ECLIPSE, GALANT, MIRAGE, PRECIS & 3000GT

         1) Remove all dirt and grease around kickdown servo switch.

Remove snap ring and kickdown servo switch.

         2) To prevent servo piston from turning, install Adapter

(MD998915) and Kickdown Servo Wrench (MD998914) so tab of wrench

engages with notch of piston. See Fig. 2.

CAUTION:  DO NOT push servo piston inward while installing adapter

          and servo wrench. Install adapter in brake pressure port by

          hand ONLY. DO NOT use wrench to tighten adapter.

Fig. 2:  Adjusting Kickdown Servo (Except Montero & Pickup)

Courtesy of Mitsubishi Motor Sales of America.

         3) Loosen lock nut to "V" channel of adjuster rod. See

Fig. 2. Tighten inner section of Kickdown Service Adjustment Assembly

(MD998916) until it contacts lock nut.

         4) Install outer section of kickdown service adjustment

assembly on lock nut. Rotate outer section to left and inner section

to right to contact lock nut with inner section.

         5) Using an INCH lb. torque wrench on inner section, tighten

inner section to 86 INCH lbs. (9.8 N.m), and then loosen inner

section. Tighten inner section to 43 INCH lbs. (4.9 N.m).

CAUTION:  Before tightening lock nut with torque wrench, tighten it

          by hand until it contacts piston. If torque wrench is used

          initially, lock nut and adjustment rod may rotate together.

         6) Back off outer section 2-2 3/4 turns. Rotate outer section

to right and inner section to left until inner section is free of lock

nut. Tighten lock nut by hand until it contacts piston. Using torque

wrench, tighten lock nut to 18-23 ft. lbs. (25-32 N.m).

         7) Remove adapter and kickdown servo wrench. Install new "O"

ring in groove around switch. Install switch and snap ring.

         TRANSMISSION THROTTLE CONTROL

         MIRAGE

         1) On all other models, ensure throttle lever is in curb idle

position. Engine must be at normal operating temperature.

         2) On all models, raise cover "B" of throttle cable upward to

expose nipple. See Fig. 3. Loosen lower cable bracket mounting bolt.

Move lower cable bracket until distance between nipple and top of

cover "A" on throttle cable is .02-.06" (.5-1.5 mm).

         3) Tighten lower cable bracket mounting bolt to 108-126 INCH

lbs. (12-14 N.m). With throttle lever in wide open throttle position,

pull cable upward to ensure some cable free play exists.

Fig. 3:  Adjusting Throttle Cable (Mirage)

Courtesy of Mitsubishi Motor Sales of America.

CAUTION:  On Pickup, always adjust throttle control cable

          whenever idle is adjusted.

         PICKUP

         1) Ensure engine idle is adjusted correctly. Ensure throttle

lever and throttle cable bracket are not bent. Pull lightly on inner

throttle cable.

         2) While in closed throttle position, measure gap between

inner cable stopper and outer cable housing. Adjust cable as necessary

to obtain a gap of .031-.059" (.79-1.50 mm). See  Fig. 4 (STEP 1).

Fig. 4:  Adjusting Throttle Cable (Pickup)

Courtesy of Mitsubishi Motor Sales of America.

         3) While holding throttle in wide open position, pull on

inner throttle cable. Adjust bell crank as necessary to obtain a gap

of 1.46-1.50" (37.08-38.10 mm) between inner cable stopper and outer

cable. See Fig. 4 (STEP 2).

         4) With throttle fully closed, recheck gap between inner

cable stopper and outer cable housing. Gap should be .031-.059" (.79-

1.50 mm). See Fig. 4 (STEP 3). While holding throttle in wide open

position, pull on inner throttle cable. Check for a gap of 1.30-1.38"

(33.02-35.05 mm).

         Montero    Ensure throttle lever and throttle cable bracket

are not bent. Ensure distance between inner cable stopper end and dust

cover is 0-.04" (0-1.0 mm). See Fig. 5.

Fig. 5:  Adjusting Throttle Cable (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         SHIFT LINKAGE