Mitsubishi Montero, Sport 1998-06

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Transmission and transfer case shift lever assembly. On manual transmissions
     
    Transfer case protector, if equipped
     
    Front exhaust pipe from the 2 exhaust manifolds, then disconnect it from the intermediate pipe/catalytic converter (make certain to retain the bolts and nuts for reassembly).
     
    Rear driveshaft at both the rear axle and the transfer case flanges. Matchmark for reassembly.
     
    Front driveshaft from the front axle, by sliding it forward, plug the transfer case to prevent residual fluid leakage. On 4-wheel drive vehicles
     
    Dust seal from the rear extension housing.
     
    Ground cables
     
    4WD indicator light switch connector
     
    Pulse generator connector
     
    Speed Sensor Connector
     
    Oxygen (O 2 S) sensor connector
     
    Back-up light switch connector
     
    HI/LO detection switch connector
     
    Center differential lock detection switch connection.
     

  6.  

There may be others depending on the particular year, model and engine with which the vehicle came equipped.

  1. Remove or disconnect the following:

    Speedometer cable out of the transmission
     

  2.  
  3. On manual transmissions:
  4.  
  5. Remove or disconnect the following:

    Clutch cylinder heat protector
     
    Clutch release cylinder (with the clutch hose connected to it) from the transmission. Suspend it from the body by using a piece of wire or a similarly safe method.
     
    Starter motor and the heat shield
     

  6.  
  7. On automatic transmissions:
  8.  
  9. Remove or disconnect the following:

    Bolts attaching the torque converter to the flexplate
     
    Dipstick
     
    Fluid cooling lines
     
    Shift linkage at the transmission
     

  10.  
  11. Place a floor jack and a block of wood below the engine oil pan.
  12.  
  13. Lift the floor jack under the engine just until the weight of the engine is taken onto the jack-the engine should only barely be lifted by the jack.
  14.  
  15. Use a transmission jack or second floor jack to place under the transmission. Don't support the transmission yet, only lift the jack until it is slightly below the transmission.
  16.  
  17. Remove or disconnect the following:

    Left-hand and right-hand side transmission stays from the front of the transmission, if equipped
     
    Bell housing lower cover
     
    Transfer case mounting bracket, if equipped
     

  18.  
  19. Lift the floor jack up until the transmission is being slightly supported by it.
  20.  
  21. Remove or disconnect the following:

    Transmission-to-crossmember bolts. Lift the jack about 1 / 4 in. (6mm) off of the crossmember support.
     
    Crossmember from the vehicle
     
    Transmission mounting blots. Pull the transmission away from the engine and lower it from the vehicle.
     

  22.  

To install:

  1. Lift the transmission and transfer assembly into position with the floor jack.
  2.  
  3. On the engine side, there are 2 centering locations. Be sure that the transmission mounting bolt holes are aligned with them before mounting the transmission and transfer assembly to the engine. Lowering the rear of the engine SLIGHTLY may help align the 2 assemblies.
  4.  
  5. Install or connect the following:

    Transmission assembly onto the engine making sure the aligning areas stay aligned. Torque the bolts to 54 ft. lbs. (75 Nm).
     

  6.  
  7. Lift the transmission/transfer assembly with the floor jack. Since the engine is now attached to the transmission, it also will rise slightly. Adjust its jack to keep only slight support.
  8.  
  9. Install or connect the following:

    Crossmember in place and secure with the mounting bolts. Torque the bolts to 47 ft. lbs. (65 Nm).
     
    Transmission and transfer case assembly onto the crossmember
     
    Crossmember-to-transmission bolts. Torque the bolts to 15-18 ft. lbs. (20-24 Nm) on Montero sport and to 36 ft. lbs. (49 Nm) on Montero.
     
    Mounting bracket back onto the transfer case, if equipped
     
    Bell housing lower cover
     
    Left-hand and right-hand side transmission stays
     
    Starter motor and heat shield
     
    Clutch release cylinder
     
    Speedometer cable into the transmission and secure it there with the retaining ring.
     
    Center differential lock detection switch connection
     
    HI/LO detection switch connector
     
    Back-up light switch connector
     
    O 2 S sensor connector
     
    Speed Sensor Connector
     
    Pulse generator connector
     
    4WD indicator light switch connector
     
    Ground cables
     
    Flexplate-to-torque converter bolts. Torque the bolts to 25-30 ft. lbs. (35-42 Nm). On automatic transmissions
     
    Dipstick tube
     
    Shift linkage
     
    Fluid cooler lines. Torque the line fittings to 32 ft. lbs. (44 Nm). On automatic transmissions
     

  10.  
  11. Tap the dust seal guard back onto the rear extension housing with a rubber or plastic mallet.
  12.  
  13. Install or connect the following:

    Front driveshaft into the transfer case, then attach it to the front differential
     
    Rear driveshaft, make certain that the matchmarks line up.
     
    Front exhaust pipe to the catalytic converter and the exhaust manifolds
     
    Transfer case protector, if equipped
     
    Transmission and transfer case shift lever assembly. On manual transmissions
     
    Negative battery cable to the battery
     

  14.  
  15. Refill the transmission and transfer case with oil.
  16.  
  17. Start the vehicle and check for any leaks.
  18.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Remove the skid plate.
  4.  
  5. Drain the transmission fluid. Drain the transfer case fluid.
  6.  
  7. Shift the transfer case lever in the 2H position.
  8.  
  9. Matchmark the front driveshaft by making mating marks on the differential companion flange and the flange yoke.
  10.  
  11. Matchmark the rear driveshaft by making mating marks on the differential companion flange and the outer race of the ball joint assembly.
  12.  
  13. Remove the front and rear driveshafts.
    NOTE
    Be careful not to bend the joint portion when removing the rear driveshaft, as damage to the joint boot will result. The driveshaft is made of CFRP, if a tear, chip or distortion is found on the driveshaft, replace it. Do not shock, drop or scratch the driveshaft. Once removed wrap the driveshaft with a rubber sheet of 0.039 inch thick material or shaft protector part number MR534564 so that the driveshaft is protected.

  14.  
  15. Disconnect the front exhaust pipe.
  16.  
  17. Remove the radiator shroud lower cover.
  18.  
  19. Remove the transmission fluid dipstick and guide assembly.
  20.  
  21. Disconnect the transmission control cable connection. Remove the cover.
  22.  
  23. Remove the heater hose connection retaining bracket bolts.
  24.  
  25. Remove the torque converter and drive plate connection bolts.
  26.  
  27. Disconnect the starter electrical connections. Remove the starter retaining bolts. Remove the starter from the vehicle. Remove the starter cover.
  28.  
  29. Remove the oil pan connection bolts. Remove the battery cable connection.
  30.  
  31. Remove the fluid cooler tube connection.
  32.  
  33. Remove the dynamic damper. Remove the tension wire bracket.
  34.  
  35. Support the transmission assembly using a transmission jack. Remove the transmission mount center member assembly.
  36.  
  37. Remove the transmission mount insulator assembly.
  38.  
  39. Disconnect the transmission harness connector connection.
  40.  
  41. Remove the transmission retaining bolts.
    NOTE
    The size of the mounting bolts are different, note the location for proper reinstallation

  42.  
  43. Remove the transmission/transfer case from the vehicle. Remove the ground wire.
  44.  

To install:

  1. Lift the transmission and transfer case assembly into position, using a transmission jack.
  2.  
  3. Install the transmission retaining bolts.
    NOTE
    Be sure to install the bolts in the same holes as they were removed from.

  4.  
  5. Fill the transmission and transfer case with the proper grade and type fluids.

    Click image to see an enlarged view

    Fig. Automatic transmission and transfer case-Montero

  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Remove the skid plate.
  4.  
  5. Drain the transmission fluid.
  6.  
  7. Matchmark the driveshaft by making mating marks on the differential companion flange and the outer race of the ball joint assembly. Remove the driveshaft.
  8.  
  9. On 4WD vehicles, matchmark the front driveshaft by making mating marks on the differential companion flange and the flange yoke. Remove the driveshaft.
    NOTE
    Be careful not to bend the joint portion when removing the rear driveshaft, as damage to the joint boot will result. Once removed wrap the driveshaft so that it protected.

  10.  
  11. Disconnect the catalytic converter and the front exhaust pipe.
  12.  
  13. Remove the transmission fluid dipstick guide. Remove the dust shield cover.
  14.  
  15. On 2WD vehicles, disconnect the transmission control cable connection.
  16.  
  17. Disconnect the ground cable. Disconnect the speed sensor connection. Disconnect the transmission range selector connection.
  18.  
  19. On 4WD vehicles, disconnect the high/low detection switch connection.
  20.  
  21. Disconnect the solenoid valve connection. Disconnect the output shaft speed sensor connection. Disconnect the input shaft speed sensor connection.
  22.  
  23. Disconnect and plug the transmission fluid lines. Remove the starter motor cover. Disconnect the starter electrical connections. Remove the starter retaining bolts. Remove the starter from the engine.
  24.  
  25. Remove the torque converter to flex plate retaining bolts.
  26.  
  27. Support the transmission assembly, using a transmission jack.
  28.  
  29. Remove the number two crossmember assembly.
  30.  
  31. On 2WD vehicles, remove the air breather pipe assembly. On 4WD vehicles, remove the rear engine mount bracket.
  32.  
  33. Remove the transmission assembly to engine retaining bolts.
    NOTE
    The size of the mounting bolts are different, note the location for proper reinstallation

  34.  
  35. Carefully remove the transmission assembly from the vehicle.
  36.  

To install:

  1. Lift the transmission assembly into position, using a transmission jack.
  2.  
  3. Install the transmission assembly retaining bolts.
    NOTE
    Be sure to install the bolts in the same holes as they were removed from.

  4.  
  5. Fill the transmission with the proper grade and type fluid.
  6.  
  7. Fill the transfer case with the proper grade and type fluid.
  8.  
  9. Check and adjust the selector lever operation, as required.
  10.  

 
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