Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide




For 1990-95 Pick-ups and Monteros, refer to the clutch switch adjustment procedures (described earlier in this section).

The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from the clutch area. When cleaning clutch surfaces, use commercially available brake cleaning solvents.

  1. Measure clutch pedal height from the floor to the top of the pedal pad, along the line of pedal travel. The height should be:

    Montero: 7.28-7.48 in. (18.5-19.0cm)
    Pick-up: 6.5-6.7 in. (16.5-17.0cm)

  3. Adjust the pedal height, if necessary, by loosening the locknut and turning the adjusting bolt or rotating clutch switch, and retighten the locknut. Now adjust the pedal play as described below.


When checking pedal play you must not move the pedal far enough to disturb the position of the hydraulic cylinder actuating rod. Move the pedal to a point where resistance stiffens but no more.

  1. For hydraulic clutches used in Monteros and later-modeled Pick-ups, loosen the locknut, and turn the pushrod to bring the play within specification. On all models, this is 0.039-0.12 in. (1-3mm). Retighten the locknut.
  3. Check the total free-play, which should be 0.24-0.47 in. (6-12mm). Check the pedal height, also. If play is not correct, bleed the system. If that does not correct play, the master cylinder or the clutch itself is faulty.
  5. On Pick-ups with the clutch cable, the clutch pedal free-play should be 0.79-1.18 in. (20-30mm). If it is outside specification, pull up gently on the cable at the floorboard and turn the outer cable adjusting nut until the nut-to-insulator clearance is about 0.098 in. (2.5mm). After making the adjustment, depress the clutch pedal to the floor several times and recheck pedal free-play.