Mitsubishi Montero (2002-2004). Manual - part 856

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-15

ESSENTIAL SERVICE

TRANSMISSION FLUID CHECK

M1231101600156

1. Drive the vehicle until the transmission fluid temperature 

rises to the normal temperature [70 

− 80°C (158 − 176°F)].

NOTE: The transmission fluid temperature is measured with 
scan tool MB991502 (MUT-II).
NOTE: If it takes some amount of time until the transmission 
fluid reaches its normal operating temperature [70 

−

 80 

°

C 

(158 

−

 176

°

F)], check the transmission fluid level by refer-

ring to the left diagram.

2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque 

converter and the hydraulic circuits with fluid, and then move 
the selector lever to the "N" position.

4. After wiping off any dirt around the dipstick, remove the 

dipstick and check the condition of the transmission fluid.
NOTE: If the transmission fluid smells as if it is burnt, it 
means that the transmission fluid has been contaminated by 
fine particles from the bushings and friction materials. A 
transmission overhaul and cooler line flushing may be nec-
essary.

ACX00213

DATA LINK
CONNECTOR

AJ

T

AC203914

AC

U

ACCELERATOR PEDAL
POSITION SENSOR

STEERING
SHAFT

ACX02208 AF

STOPLIGHT
SWITCH

BRAKE PEDAL

V

AC100600

HOT

AB

FLUID LEVEL [mm (in)]

10 (0.4)

0 (0)

–10 (–0.4)

–20 (–0.8)

20 (0.8)

–30 (–1.2)

–40 (–1.6)

40
(104)

60
(140)

80
(176)

FLUID TEMPERATURE [˚C (˚F)]

DIPSTICK

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-16

5. Check that the transmission fluid level is at the "HOT" mark 

on the dipstick. If the transmission fluid level is less than 
this, add DIAMOND ATF SP III or equivalent transmission 
fluid until the level reaches the "HOT" mark.
NOTE: If the transmission fluid level is too low, the oil pump 
will draw in air along with the transmission fluid, which will 
cause bubbles to form. If the transmission fluid level is too 
high, rotating components inside the transmission will churn 
the fluid and air into a foamy liquid. Both conditions (level 
too low or too high) will cause the hydraulic pressure to 
drop, which will result in late shifting and slipping of the 
clutches and brakes.
In either case, air bubbles can interfere with normal valve, 
clutch, and brake operation. Also, foaming can cause trans-
mission fluid to escape from the transmission vents where it 
may be mistaken for a leak.

6. Securely insert the dipstick.

NOTE: The transmission fluid should always be replaced 
under the following conditions:

.

•

When troubleshooting the transmission

•

When overhauling the transmission

•

When the transmission fluid is noticeably dirty or burnt 
(driving under severe conditions)

TRANSMISSION FLUID REPLACEMENT

M1231101700153

If you have an transmission fluid changer, use it to replace the 
transmission fluid. If you do not have an transmission fluid 
changer, replace the transmission fluid by the following proce-
dure.
1. Disconnect the hose shown in the illustration which 

connects the transmission and the oil cooler (inside the 
radiator). Place a container under the hose to collect the 
discharge.

CAUTION

The engine should be stopped within one minute after it is 
started. If all the transmission fluid has drained out before 
then, the engine should be stopped at that point. 
2. Start the engine and let the transmission fluid drain out.

(Running conditions: "N" range with engine idling.)

Discharge volume: Approximately 4.0 dm

3

 (4.2 quarts)

3. Remove the drain plug from the bottom of the transmission 

case to drain the transmission fluid.

Discharge volume: Approximately 2.0 dm

3

 (2.1 quarts)

4. Install the drain plug with a new gasket, and tighten it to the 

specified torque.

Tightening torque: 39 

± 5 N⋅m (29 ± 3 ft-lb)

AC000846AC

ACX01184

AB

ACX01185AB

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-17

CAUTION

Stop pouring if the full volume of transmission fluid can 
not be added.
5. Add new transmission fluid (DIAMOND ATF SP III or 

equivalent) through the oil filter tube.

Adding volume: Approximately 6.0 dm

3

 (6.3 quarts)

6. Repeat the procedure in Step 2. (to pump out the rest of the 

contaminated transmission fluid)

7. Add new transmission fluid (DIAMOND ATF SP III or 

equivalent) through the oil filler tube. 

Adding volume: Approximately 4.0 dm

3

 (4.2 quarts)

NOTE: Check for contamination or a burnt odor. If the trans-
mission fluid is still contaminated or burnt, repeat Steps 6 
and 7 before proceeding to Step 8.

8. Reconnect the hose which was disconnected in step 1 

above, and firmly replace the dipstick.

9. Start the engine and run it at idle for one to two minutes.
10.Move the selector lever through all positions, and then move 

it to the "N" position.

11.Check that the transmission fluid level is at the "COLD" 

mark on the dipstick. If the level is less than this, add 
transmission fluid.

12.Drive the vehicle until the transmission fluid temperature 

rises to the normal operating temperature [70 

− 80°C (158 − 

176

°F)], and then check the transmission fluid level again. 

The transmission fluid level must be at the "HOT" mark.
NOTE: The transmission fluid temperature is measured with 
scan tool MB991502 (MUT-II).
NOTE: The "COLD" level is for reference only; the "HOT" 
level should be regarded as the standard level.
NOTE: If it takes some amount of time until the transmission 
fluid reaches its normal operating temperature [70 

−

 80 

°

C 

(158 

−

 176

°

F)], check the transmission fluid level by refer-

ring to the left diagram.

13.When the transmission fluid is less than the specified level, 

add transmission fluid.
When the transmission fluid is greater than the specified 
level, drain the excess fluid through the drain plug to adjust 
the transmission fluid to the specified level.

14.Firmly insert the dipstick into the oil filler tube.

ACX01184

AB

AC000846AC

AC100600

HOT

AB

FLUID LEVEL [mm (in)]

10 (0.4)

0 (0)

–10 (–0.4)

–20 (–0.8)

20 (0.8)

–30 (–1.2)

–40 (–1.6)

40
(104)

60
(140)

80
(176)

FLUID TEMPERATURE [˚C (˚F)]

DIPSTICK

ON-VEHICLE SERVICE

TSB Revision

AUTOMATIC TRANSMISSION

23Aa-18

FLUSHING COOLERS AND TUBES

M1231104800159

Required Special Tool:

• MB995062: Flushing Tool

WARNING

•

Wear protective eyewear that meets the require-
ments of and ANSI Z87.1 

− 1968 and OSHA. Wear 

standard industrial rubber gloves.

•

Keep lighted cigarettes, sparks, flames, and other 
ignition sources away from the area to prevent the 
ignition of combustible liquids and gases. Keep a 
class B fire extinguisher in the area where the 
flushing tool will be used. Keep the area well venti-
lated. Do not let flushing solvent come in contact 
with eyes or skin. If it does, flush with water for 15 
to 20 seconds. Remove contaminated clothing and 
wash affected skin with soap and water. Seek med-
ical attention.

When a transmission failure has contaminated the transmission 
fluid, the oil cooler(s) must be flushed. The cooler by-pass 
valve in the transmission must also be replaced. The torque 
converter must also be replaced with an exchange unit. This 
will ensure that metal particles or sludged transmission fluid are 
not later transferred back into the reconditioned (or replaced) 
transmission. There are two different procedures for flushing 
coolers and lines. The recommended procedure is to use spe-
cial tool MB995062 Flushing Tool. The other procedure is to 
use a hand suction gun and mineral spirits.
1. Remove the cover plate filler plug on special tool 

MB995062. Fill the reservoir 1/2 to 3/4 full with fresh flushing 
solution. Flushing solvents are petroleum based solutions 
generally used to clean transmission components. Do not 
use solvents containing acids, water, gasoline, or any other 
corrosive liquids.

2. Reinstall the filler plug on special tool MB995062.
3. Verify that the pump power switch is turned "OFF." Connect 

the red alligator clip to the positive battery terminal. Connect 
the black alligator clip to a good ground.

4. Disconnect the cooler lines at the transmission.

NOTE: When flushing the transmission cooler and lines, 
always reverse flush.

5. Connect the BLUE pressure line to the OUTLET line (from 

cooler.) cooler line.

6. Connect the CLEAR return line to the INLET line (to cooler.) 

cooler line.

7. Turn the pump "ON" for two to three minutes to flush the 

cooler(s) and lines. Monitor the pressure readings. Clear the 
return lines. Pressure readings should stabilize below 138 
kPa (20 psi) for vehicles equipped with a single cooler and 
208 kPa (30 psi) for vehicles equipped with dual coolers. If 
flow is intermittent or exceeds these pressures, replace the 
cooler(s).

ACX02073AB

FROM COOLER

TO COOLER