Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

Clutch Linkage

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REMOVAL & INSTALLATION



Cable-Actuated Clutches
CLUTCH CABLE

See Figures 1 and 2


CAUTION
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. From the engine compartment, pull the clutch cable out and turn the adjusting nut counter-clockwise to increase the cable play (which will allow the cable to be easier to remove from the clutch lever.
  2.  
  3. From inside of the vehicle, unhook the cable from the clutch lever.
  4.  
  5. From back in the engine bay, pull the cable out through the firewall.
  6.  
  7. Raise the vehicle and safely support it on jackstands.
  8.  
  9. The other end of the clutch cable attaches to the left-hand side of the front of the transmission. Remove the cotter pin holding it in place.
  10.  
  11. Unhook the cable end from the transmission lever, then pull the cable out of the transmission mounting hole.
  12.  
  13. Pull the cable out of the engine mount insulator bracket. Retain the insulator pad for assembly.
  14.  



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Fig. Fig. 1: Clutch cable removal and installation



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Fig. Fig. 2: Make sure to route the cable so that it is retained by the engine mount insulator

  1. To install the cable, route it through the engine mount insulator bracket, making sure that the insulator pad is pushed into the bracket (this protects the cable from rubbing against the bracket).
  2.  
  3. Insert the transmission end of the cable through the transmission mounting hole, then hook the cable to the lever.
  4.  
  5. Install a new cotter pin to retain the cable in the transmission.
  6.  
  7. Lower the vehicle back to the ground.
  8.  
  9. Slide the cable through the firewall hole as far as it will go.
  10.  
  11. From inside the vehicle, hook the cable to the clutch lever.
  12.  
  13. Adjust the clutch pedal and cable-refer to the clutch switch procedures in this section.
  14.  

TRANSMISSION INNER-LINKAGE

See Figures 3, 4, 5 and 6

  1. To remove the inner linkage of the clutch system, the transmission will have to be removed from the vehicle. To do this, follow the previously outlined instructions in this section.
  2.  
  3. With the transmission out of the vehicle, remove the retaining clips from the clutch release bearing (located on the transmission end shaft.
  4.  
  5. Slide the release bearing off of the shaft.
  6.  
  7. Using a punch with the same outside diameter as the spring clips (two are located in the release fork), tap the spring clips out of the release fork. Discard the old spring clips, new ones will be needed for reassembly.
  8.  
  9. Slide the release fork shaft out of the transmission, making sure to account for the two pieces of packing, the right-hand return spring, the left-hand return spring and the release fork. Note the positions of these components for reassembly.
  10.  
  11. If need be, remove the weight from the release fork shaft.
  12.  



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Fig. Fig. 3: Install the two new spring clips with the slits facing the tongs on the release fork



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Fig. Fig. 4: Use a punch to remove the old and install the new spring clips from the release fork-cable-actuated clutch systems



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Fig. Fig. 5: Grease the areas shown on the inner-surface of the release bearing-all clutch systems are similar



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Fig. Fig. 6: Inner-transmission and clutch plate removal and installation-cable-actuated clutch systems

  1. To reassemble, mount the weight back onto the release fork shaft.
  2.  
  3. Before reassembling the release fork and components, grease the release fork shaft from each end of the shaft for about 2-3 in. (25-37mm). Also grease the two front surfaces of the tongs on the release fork.
  4.  
  5. As the release fork shaft is slid into the transmission, install the inner components on the shaft. The order is: packing, left return spring, release fork, right return spring, packing.
  6.  
  7. Line the spring clip holes up with the holes on the release fork shaft, then tap new spring clips into the release fork and shaft. Make sure that the slits in the spring clips are toward the tongs on the release fork (facing toward the transmission end shaft).
  8.  


CAUTION
Do not reuse the old spring clips.

  1. Grease the inside surface of the clutch release bearing, then slide the bearing onto the transmission end shaft.
  2.  
  3. Secure the release bearing on the shaft with new retaining clips.
  4.  
  5. Install the transmission into the vehicle.
  6.  

Hydraulic Clutches
CLUTCH HOSE AND TUBE

See Figure 7

This procedure is for all hydraulic clutches with or without ABS. If the vehicle does have ABS, the ABS connection can be removed from the pipe once the entire pipe has been removed from the vehicle.

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Place a pan or similar container under the clutch hose connection to the clutch release cylinder to catch the clutch fluid.
  4.  
  5. Loosen and remove the eye bolt holding the clutch hose to the clutch release cylinder. Drain the fluid into the container.
  6.  
  7. Discard the two old eye bolt gaskets, new ones will be needed for reassembly.
  8.  
  9. Holding the nut at the clutch hose side, loosen the flare nut of the clutch tube.
  10.  
  11. Remove the clutch hose from the vehicle.
  12.  
  13. Loosen the clutch tube from the clutch master cylinder and extract the tube from the vehicle.
  14.  
  15. At this point the ABS connector can be removed from the tube if need be.
  16.  



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Fig. Fig. 7: Clutch hose and tube removal and installation

  1. To install, carefully thread the upper flare nut of the clutch tube into the clutch master cylinder, then tighten it to 10-12 ft. lbs. (13-17 Nm).
  2.  
  3. Carefully thread the lower flare nut into the upper end of the clutch hose. Once the threads are started, tighten the connection to 10-12 ft. lbs. (13-17 Nm). Take care to not let the clutch hose twist.
  4.  
  5. Connect the clutch hose to the release cylinder at the stepped portion. Make sure to use two new gaskets on the clutch hose connection. Tighten the eye bolt to 14-18 ft. lbs. (20-25 Nm).
  6.  
  7. Fill the master cylinder with brake fluid meeting SAE J1703 (DOT3) specifications.
  8.  


WARNING
Use the specified brake fluid. Avoid using a mixture of the specified fluid and another fluid.

  1. Bleed the system until no air remains in it.
  2.  
  3. Check for clutch fluid leaks at all connections in the system.
  4.  

TRANSMISSION INNER LINKAGE



See Figures 8, 9 and 10

To service the inner linkage, the transmission must first be removed from the vehicle.

  1. With the transmission removed from the vehicle, remove the return spring.
  2.  
  3. Slide the clutch release bearing off of the transmission end shaft.
  4.  
  5. Remove the release cylinder from the side of the transmission.
  6.  
  7. Pop the release fork boot out of the transmission hole.
  8.  
  9. Slide the release fork toward the boot hole in the transmission. This will disengage the fulcrum from the retaining clip. Be careful not to cause any damage to the clip by pushing the release fork in the direction other than that of toward the transmission boot hole or by removing it with force.
  10.  
  11. If needed, unscrew the fulcrum from the transmission.
  12.  



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Fig. Fig. 8: Inner-transmission clutch linkage and clutch plate removal and installation-hydraulic clutch systems



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Fig. Fig. 9: Slide the release fork toward the release fork boot hole in the transmission to unhook the retainer clip-hydraulic clutch systems



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Fig. Fig. 10: Grease the release fork at the positions shown prior to installation-hydraulic clutch systems

  1. Before reassembly the following areas must be greased with Mitsubishi genuine grease Part No. 0101011 or its equivalent:

    The fulcrum pivot-point on the release fork.
     
    The release cylinder pivot-point on the release fork.
     
    The release bearing pivot-point of the release fork.
     
    The inner-surface of the release bearing.
     

  2.  
  3. Screw the fulcrum back into the transmission and tighten to 26 ft. lbs. (36 Nm).
  4.  
  5. Insert the thin end of the release fork through the transmission boot hole from the inside. Slide the fork onto the fulcrum and make sure the clip engages the fulcrum pivot-point.
  6.  
  7. Slide the release fork boot over the outside end of the fork and install it to the transmission hole.
  8.  
  9. Mount the release cylinder onto the outside of the transmission, making sure that the actuating rod fits into the indent on the release fork.
  10.  
  11. Slide the release bearing onto the transmission end shaft (make sure the bearing has already been greased). Make certain that the release bearing is installed facing the correct direction.
  12.  
  13. Install the return spring.
  14.  
  15. Install the transmission into the vehicle.
  16.  

 
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