Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

Adjustments

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BAND ADJUSTMENT



1990-95 Pick-Ups
KICKDOWN BAND (FRONT)

See Figure 1

The kickdown band adjusting screw is located on the left side of the transmission case.

  1. Loosen the locknut and back the nut off approximately five turns. Make sure the screw turns freely within the transmission case.
  2.  
  3. Using a torque wrench, tighten the adjusting screw to 72 inch lbs. (8 Nm).
  4.  
  5. Back the adjusting screw out 2 7 / 8 turns. Hold the adjusting screw in place, then tighten the locknut to 30 ft. lbs. (41 Nm).
  6.  



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Fig. Fig. 1: The kickdown band adjusting screw is in the same location for both the R4AC1 and the MA 904A transmissions

LOW-REVERSE BAND (REAR)

See Figure 2

  1. Raise the vehicle and safely support it on jackstands.
  2.  
  3. Loosen the transmission pan, drain the fluid into a container and remove the pan from the transmission.
  4.  
  5. Loosen the adjusting screw and locknut, then back the nut off approximately five turns. Test the adjusting screw for free turning in the lever.
  6.  
  7. Tighten the band adjusting screw to 30 inch lbs. (3.5 Nm).
  8.  
  9. Back the adjusting screw out 6 turns. Hold the adjusting screw in this position, and tighten the locknut to 25 ft. lbs. (34 Nm).
  10.  
  11. Reinstall the transmission pan using a new gasket. Tighten the transmission pan bolts to 12.5 ft. lbs. (17 Nm).
  12.  
  13. Fill the transmission with the specified fluid.
  14.  



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Fig. Fig. 2: To gain access to the low-reverse band adjusting screw, the transmission pan must be removed-make sure to have new gaskets for reassembly

1983-86 Pick-Ups and Monteros
KICKDOWN BAND (FRONT)

The kickdown band adjusting screw is located on the left side of the transmission case.

  1. Loosen the locknut and back the nut off approximately five turns. Make sure the screw turns freely within the transmission case.
  2.  
  3. Using a torque wrench, tighten the adjusting screw to 5.8 ft. lbs. (7.8 Nm).
  4.  
  5. Back the adjusting screw out 3 1 / 2 turns. Hold the adjusting screw in place, then tighten the locknut to 30-41 ft. lbs. (40-55 Nm).
  6.  

LOW-REVERSE BAND (REAR)

For this procedure the Mitsubishi tool MD998358 will be needed.

  1. Raise the vehicle and safely support it on jackstands.
  2.  
  3. Loosen the transmission pan, drain the fluid into a container and remove the pan from the transmission.
  4.  
  5. Loosen the adjusting screw and locknut, then back the nut off approximately five turns. Test the adjusting screw for free turning in the lever.
  6.  
  7. Tighten the band adjusting screw with the tool MD998358 to 3.6 ft. lbs. (4.9 Nm).
  8.  
  9. Back the adjusting screw out 7 turns. Hold the adjusting screw in this position, and tighten the locknut to 25-35 ft. lbs. (34-47 Nm).
  10.  
  11. Reinstall the transmission pan using a new gasket. Tighten the transmission pan bolts to 11-14 ft. lbs. (15-20 Nm).
  12.  
  13. Fill the transmission with the specified fluid.
  14.  

SHIFTER CONTROL LINKAGE



1983-86 Pick-Ups and Monteros
  1. Set the transmission shifter to the N position.
  2.  
  3. Turn the rod adjusting cam to adjust the distance from the end of the selector lever to the end of the rod adjusting cam as indicated in the illustration.
  4.  
  5. After the adjustment, move the lever through all the ranges to confirm that it moves smoothly and operates correctly.
  6.  

KICKDOWN LINKAGE ADJUSTMENT



1983-86 Pick-Ups and Monteros

See Figures 3 and 4

When the idle speed is adjusted, the throttle linkage will need adjusting.

  1. Loosen the bolts so that rods B and C can slide properly.
  2.  
  3. Allow the engine to warm up until the engine coolant temperature reaches the average operating temperature of 170°F (80°C). Confirm complete release of the fast idle. This confirmation can be made by checking to see if the cam surface of the choke lever of the carburetor is completely off the cam follower of the throttle lever.
  4.  
  5. Lightly pushrod A or the transmission throttle lever toward the idle stopper (toward the back of the transmission), and set the rods to the idle position. Tighten the bolt securely to connect rods B and C.
  6.  
  7. Make sure that, when the carburetor throttle valve is wide open, the transmission throttle lever moves with an operating angle of 47.5-54° of movement. Make sure that, when the throttle linkage alone is slowly returned from the fully opened position, the transmission throttle lever completely returns to idle by return spring force.
  8.  



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Fig. Fig. 3: Throttle rod (kickdown) system-MA904A transmissions



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Fig. Fig. 4: Check the movement range of the throttle lever on the transmission when finished adjusting the rods

1987-89 Pick-Ups and Monteros

See Figure 5

  1. Check and adjust the idle speed.
  2.  

When the engine idle adjustment has been performed, always adjust the throttle control cable.

  1. Make certain no bend or deformation is present in either the carburetor throttle lever or the cable mounting bracket.
  2.  
  3. Measure the length between the inner cable stopper and the cover end with the throttle wide open.
  4.  
  5. Correct measurement is 2.05-2.09 in. (52-53mm). If the cable is out of specification, adjust the inner cable bracket by moving it up or down as needed.
  6.  



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Fig. Fig. 5: The kickdown adjustment set up on the AW372 and KM148 transmissions

1990-95 Pick-Ups

See Figures 6, 7, 8 and 9

  1. Make sure that the kickdown cable is correctly attached to the bell crank lever.
  2.  
  3. Pull on the inner kickdown cable (transmission end) while the throttle lever is held in the idle position.
  4.  
  5. While the inner cable is being pulled, adjust the inner cable stopper so that the space between the stopper and the outer cable becomes 0.031-0.059 in. (0.8-1.5mm).
  6.  
  7. Pull the inner cable (transmission end) and hold the throttle lever to the full open position. With this position being maintained, loosen and adjust the length of the bell crank lever arm so that the space between the inner cable stopper and the outer cable becomes 1.46-1.50 in. (37-38mm).
  8.  
  9. After adjusting the engine to the regular idling position, fix the inner cable to the throttle lever (engine end of cable). At this time, fasten the outer cable with the adjusting nuts so that the space between the inner cable stopper and the outer cable becomes 0.031-0.05 in. (0.8-1.5mm).
  10.  
  11. With the throttle lever (engine end) being fully open, confirm that the space between the outer cable and the inner cable is 1.30-1.38 in. (33-35mm).
  12.  



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Fig. Fig. 6: Make sure that the kickdown cable is securely attached to the bell crank lever before adjusting the cable



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Fig. Fig. 7: Move the inner cable stopper to change the clearance at idle-the clearance should be 0.8-1.5mm (0.031-0.05 in.)



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Fig. Fig. 8: Measure the clearance when the cable is pulled all the way to the wide open position



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Fig. Fig. 9: Once finished with the adjustment, check the clearances on the engine end of the cable

1990-95 Monteros
3.5L AND 1990-94 3.0L ENGINES

See Figure 10

  1. Check for a defective or bent throttle lever or throttle cable bracket.
  2.  
  3. With the accelerator depressed, check that the distance between the inner cable stopper and dust cover surface is within 0-0.4 in. (0-1mm).
  4.  
  5. If the distance is outside of the standard value, adjust using the adjusting nut on the bracket.
  6.  



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Fig. Fig. 10: Adjust the clearance by turning the adjusting nut-3.0L and 3.5L engines 1990-94

1995 3.0L ENGINES

See Figure 11

  1. Make sure that the throttle lever and the bracket have no deformations or damage.
  2.  
  3. Remove the boot at the outer cable so that the inner cable stopper can be seen.
  4.  
  5. Measure the dimension between the end of the inner cable stopper and that of the outer cable with the throttle lever fully open. The standard value is 1.34-1.38 in. (34-35mm).
  6.  
  7. If the distance is outside the standard value, adjust using the adjusting nut on the bracket.
  8.  



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Fig. Fig. 11: To correctly adjust the cable, the boot must first be removed-adjust the cable by turning the adjusting nut

THROTTLE PRESSURE ADJUSTMENTS



See Figure 12

1983-86 Pick-Ups And Monteros

Throttle pressures cannot be tested accurately; therefore, the adjustment should be measured if a malfunction is evident. For this procedure you will need the Mitsubishi tool MIT3763 Throttle Pressure Adjust Tool.

  1. Insert the special tool between the throttle lever cam and the kickdown valve.
  2.  
  3. By pushing in on the tool, compress the kickdown valve against its spring so that the throttle valve is completely bottomed inside the valve body.
  4.  



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Fig. Fig. 12: Use the special tool (either MIT3763 or C-3763) to depress the kickdown valve while tightening the throttle lever-MA 904A and R4AC1 transmissions

  1. As force is being exerted to compress the spring, turn the throttle lever stop screw with an allen wrench until the head of the screw touches the throttle lever tang with the throttle lever cam touching the tool and the throttle valve bottomed. Be sure the adjustment is made with the spring fully compressed and the valve bottomed in the valve body.
  2.  

1990-95 Pick-Ups

Throttle pressures cannot be tested accurately; therefore, the adjustment should be measured if a malfunction is evident. For this procedure you will need the Mitsubishi Tool C-3763.

  1. Insert the special tool between the throttle lever cam and the kickdown valve.
  2.  
  3. By pushing in on the tool, compress the kickdown valve against its spring so that the throttle valve is completely bottomed inside the valve body.
  4.  
  5. As force is being exerted to compress the spring, turn the throttle lever stop screw with an allen wrench until the head of the screw touches the throttle lever tang with the throttle lever cam touching the tool and the throttle valve bottomed. Be sure the adjustment is made with the spring fully compressed and the valve bottomed in the valve body.
  6.  

 
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